Cargo container for storing and transporting cargo

ABSTRACT

The present invention provides a cargo container that is light weight, strong, which forms an ultraviolet light, weather/dust particle barrier and which controls the climate inside the cargo container to protect the integrity of the cargo.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority and benefit of U.S. provisional patent application Ser. No. 61/832,959, filed Jun. 9, 2013, entitled “CARGO CONTAINER FOR STORING AND TRANSPORTING CARGO”, the contents of which are hereby incorporated by reference in their entirety.

This application is a Continuation-in-part of U.S. patent application Ser. No. 13/549,472, filed Jul. 15, 2012, entitled “CARGO CONTAINER FOR STORING AND TRANSPORTING CARGO”, which claimed priority to 61/551,323, filed Oct. 25, 2011, entitled “CARGO CONTAINER FOR STORING AND TRANSPORTING CARGO”, U.S. provisional patent application Ser. No. 61/508,425, filed Jul. 15, 2011, entitled “CLIMATE CONTROL CARGO CONTAINER FOR STORING, TRANSPORTING AND PRESERVING CARGO”; U.S. provisional patent application Ser. No. 61/551,340, filed Oct. 25, 2011, entitled “A LOAD BEARING STRUCTURE HAVING ANTIMICROBIAL PROPERTIES”; and U.S. provisional patent application Ser. No. 61/590,323, filed Jan. 24, 2012, entitled “SYSTEM FOR FACILITATING SECURITY CHECK OF SHIPMENT OF CARGO”; the contents of all of which are hereby incorporated by reference in their entirety.

This application is a Continuation-in-part of U.S. patent application Ser. No. 13/549,471, filed Jul. 15, 2012, entitled “CLIMATE CONTROL CARGO CONTAINER FOR STORING, TRANSPORTING AND PRESERVING CARGO”, which claimed priority to 61/551,323, filed Oct. 25, 2011, entitled “CARGO CONTAINER FOR STORING AND TRANSPORTING CARGO”, U.S. provisional patent application Ser. No. 61/508,425, filed Jul. 15, 2011, entitled “CLIMATE CONTROL CARGO CONTAINER FOR STORING, TRANSPORTING AND PRESERVING CARGO”; U.S. provisional patent application Ser. No. 61/551,340, filed Oct. 25, 2011, entitled “A LOAD BEARING STRUCTURE HAVING ANTIMICROBIAL PROPERTIES”; and U.S. provisional patent application Ser. No. 61/590,323, filed Jan. 24, 2012, entitled “SYSTEM FOR FACILITATING SECURITY CHECK OF SHIPMENT OF CARGO”; the contents of all of which are hereby incorporated by reference in their entirety.

This application is a Continuation-in-part of U.S. patent application Ser. No. 13/549,474, filed Jul. 15, 2012, entitled “A LOAD BEARING STRUCTURE HAVING ANTIMICROBIAL PROPERTIES”, which claimed priority to 61/551,323, filed Oct. 25, 2011, entitled “CARGO CONTAINER FOR STORING AND TRANSPORTING CARGO”, U.S. provisional patent application Ser. No. 61/508,425, filed Jul. 15, 2011, entitled “CLIMATE CONTROL CARGO CONTAINER FOR STORING, TRANSPORTING AND PRESERVING CARGO”; U.S. provisional patent application Ser. No. 61/551,340, filed Oct. 25, 2011, entitled “A LOAD BEARING STRUCTURE HAVING ANTIMICROBIAL PROPERTIES”; and U.S. provisional patent application Ser. No. 61/590,323, filed Jan. 24, 2012, entitled “SYSTEM FOR FACILITATING SECURITY CHECK OF SHIPMENT OF CARGO”; the contents of all of which are hereby incorporated by reference in their entirety.

This application is a Continuation-in-part of U.S. patent application Ser. No. 13/549,477, filed Jul. 15, 2012, entitled “SYSTEM FOR FACILITATING SECURITY CHECK OF SHIPMENT OF CARGO”, which claimed priority to 61/551,323, filed Oct. 25, 2011, entitled “CARGO CONTAINER FOR STORING AND TRANSPORTING CARGO”, U.S. provisional patent application Ser. No. 61/508,425, filed Jul. 15, 2011, entitled “CLIMATE CONTROL CARGO CONTAINER FOR STORING, TRANSPORTING AND PRESERVING CARGO”; U.S. provisional patent application Ser. No. 61/551,340, filed Oct. 25, 2011, entitled “A LOAD BEARING STRUCTURE HAVING ANTIMICROBIAL PROPERTIES”; and U.S. provisional patent application Ser. No. 61/590,323, filed Jan. 24, 2012, entitled “SYSTEM FOR FACILITATING SECURITY CHECK OF SHIPMENT OF CARGO”; the contents of all of which are hereby incorporated by reference in their entirety.

FIELD OF THE INVENTION

This invention is in the general field of load-bearing structures. The loading bearing structures include dunnage platforms and cargo containers that are light weight and strong, suitable for containing the cargo during storage and transportation.

BACKGROUND OF THE INVENTION

A shipping pallet is a well-known load-bearing, moveable platform whereon articles are placed for shipment. The pallet usually is loaded with a multiplicity of items, such as cartons or boxes. The loaded pallet is movable with either a pallet truck or a forklift.

The adoption of International Standardized Phytosanitary Monitoring (ISPM)-15 for wood packaging material (WPM) requires kiln dry treatment of all wood used in shipping crates and dunnage platforms (pallets). The United States in cooperation with Mexico and Canada began enforcement of the ISPM 15 standard on Sep. 16, 2005. The North American Plant Protection Organization (NAPPO) strategy for enhanced enforcement will be conducted in three phases. Phase 1, Sep. 16, 2005 through Jan. 31, 2006, call for the implementation of an informed compliance via account managers and notices posted in connection with cargo that contains noncompliant WPM. Phase 2, Feb. 1, 2006 through Jul. 4, 2006, calls for rejection of violative crates and pallets through re-exportation from North America. Informed compliance via account managers and notices posted in cargo with other types of non-compliant WPM continues to remain enforce. Phase 3, Jul. 5, 2006, involves full enforcement on all articles of regulated WPM entering North America. Non-compliant regulated WPM will not be allowed to enter the United States. The adoption of ISPM-15 reflects the growing concern among nations about wood shipping products enabling the importation of wood-boring insects, including the Asian Long horned Beetle, the Asian Cerambycid Beetle, the Pine Wood Nematode, the Pine Wilt Nematode and the Anoplophora Glapripwnnis.

Thus the wooden dunnage platform has become unattractive for the international shipment of products. Further, the wooden surface is not sanitary since it potentially can harbor in addition to insects, mould and bacteria. Thus, the wooden crate is generally ill-suited for the shipment of foodstuffs and other produce requiring sanitary conditions. In addition, with the concern for carbon emission, lighter weight platforms and containers are more desirable. Plastic dunnage platforms or pallets are known, see U.S. Pat. No. 3,915,089 to Nania, and U.S. Pat. No. 6,216,608 to Woods et al., which are herein incorporated by reference in their entirety. Thermoplastic molded dunnage platforms are known, see for example U.S. Pat. Nos. 6,786,992, 7,128,797, 7,927,677, 7,611,596, 7,923,087, and 7,544,262, which are herein incorporated by reference in their entirety, discloses applying thermoplastic sheets to a preformed rigid structure for manufacturing dunnage platforms.

While the plastic surface of the plastic pallet obviates some of the sanitary problems with wood pallets, because of the required repetitive use the surface can become unsanitary. As a consequence when used for the shipment of foodstuffs and other produce requiring sanitary conditions, the plastic surface are cleaned and kept clean prior to use.

Some wood pallet manufacturers have attempted to produce a more sanitary surface by combining foam with wooden surfaces. These dunnage platforms still suffer a number of disadvantages including their weight, the presence of wood requiring kiln treatment and the possibility of the foam being stripped away to expose the wood surface.

U.S. Pat. No. 7,689,481 discloses a dunnage platform bag and system of loading, dispensing and using the bag, which is herein incorporated by reference in its entirety.

U.S. Pat. No. 7,963,397 discloses a modular knock-down, light weight cargo container, which is herein incorporated by reference in its entirety

SUMMARY OF THE INVENTION

The present invention relates to containers for shipping and/or storage of cargo. The container is light weight and may include one or more enclosures therein. The container may be ‘knocked-down’ or collapsed to varying degrees when not in use to conserve storage space and may include a plurality of components that are easily assembled and disassembled. The various components may include interlocking features that may be similar or complementary for use in assembling the container. The interlocking features are generally located on the outer portions of the components. The components may also be of similar or different shapes and dimensions so long as they interconnect to form the container with one or more enclosures therein.

In one exemplary embodiment of the invention, a ‘knock down’ or collapsible container structure for storage and/or shipping cargo having components, such as a base, four load containing structures, for example, four walls, extending therefrom and a top panel to form, for example, a closed enclosure therein, each of which having an inside surface, an outside surface, a width or thickness joining the inside and outside surfaces, and four inside edges and four outside edges. The container when collapsed or ‘knocked-down’ to varying degrees has a foot print not larger than the foot print of the largest individual component of the structure.

In an embodiment of the invention, each of the base, four walls and top includes a continuous feature extending substantially along a surface of, for example, no more than approximately 80 percent, more for example, no more than approximately 90 percent of any of the four inside edges of any of the walls, base and top components of the container, the features on adjacent members are of opposite or complementary interlocking characteristics. That is, if an edge has a groove, the groove is, for example, less than about 80 percent, more for example, less than about 90 percent, of the length of the edge, and the adjacent member may have a protruding feature for mating with the groove.

In the embodiments described above, the percentages of the features present discussed above may also determine the location of the features as to how far away they are from the peripheral edges of the components as well as the size of the enclosure as compare to the size of the components.

Some components of the container may include dunnage platforms and those useful for assembling may include interconnecting or interlocking features or characteristics which mate together to form a container. Interlocking features or characteristics may include respective receiving and protruding characteristics such as depressions, channels, ridges and protrusion features on adjacent connecting components. For example, when the features along one side have a receiving characteristic, the features on the adjacent member are of a protruding characteristic so that the interlocking features mate to form a container without any aid from additional clips or fasteners. The phrase ‘without requiring a fastener’ means that the interlocking features may be interlocked without the aid of any component that is not the container components, such as the base, the four walls or the top. Additional securing devices may be employed to insure further integrity of the container, if needed, and such additional securing devices may include straps and/or shrink wrap packaging.

In another embodiment of the invention, the components of the knock-down container, for example, the base and load containing components, for example, four walls, and/or a top, each of the walls, top and/or base may generally include an inside surface, an outside surface, a thickness connecting the inside and outside surfaces, four outside edges and four inside edges, and may include a continuous feature extending continuously all around the inside edges of the inside surface. The features present on the components for aiding in forming the container may be similar or different, as mentioned above. These interlocking features or characteristics may be similar or complementary depending on the feature or characteristic. For example, the different features are generally complementary features when they are present in component meant to be adjacent to each other when assembled.

The feature on the edge of the base or top may include a groove, a channel, a protrusion, a ridge, a step edge configuration or combinations thereof, and those features on the edges of any of the walls that mate with the features on the edge of the base or top may be a complementary groove, a channel, a protrusion, a ridge, a step edge or combinations thereof.

The feature on the edge of any of the walls that mates with features on the edge of any other walls may be of different configurations for forming a better locking.

In one embodiment, for example, the same interface features may be present on three edges of each of the walls and a different interface feature present on the fourth edge of the wall. Each of the walls may include a rectangular or square outside surface, with a main platform portion being of the same configuration, but of a smaller rectangle or square than the dimension of the outside surface. Extending from the main platform portion of each of the walls may be a step edge on each of three edges of the walls, and an extension from the outside edge of the fourth edge, the extension having a thickness and wraps at a substantially 90° angle about a portion of the inside edge, forming a channel therebetween the inside and outside surface. The wrapping portion may be of a shape that when assembled, gives the corners of the container a rounded, chamfered and/or otherwise smooth shaped edges such that sharp and/or pointed portions of the container may be minimized.

In another embodiment, each of the walls may include a rectangular or square outside surface, with a main platform portion being of the same, but of a smaller rectangle or square than the dimension of the outside surface. Extending from the main platform portion of each of the walls may be a step edge on each of two edges of the walls, a channel surrounding the main platform on one edge of the walls and an edge surrounding the channel, and an extension from the outside edge of the fourth edge, the extension having a thickness and wraps at a substantially 90° angle about a portion of the inside edge, forming a channel therebetween the inside and outside surface. The wrapping portion may be of a shape that when assembled, gives the corners of the container a rounded, chamfered and/or otherwise smooth shaped edges such that sharp and/or pointed portions of the container may be minimized. The step edge interface feature of one side of the adjacent wall mates to the channel formed and the wrapping portion secured the mating portions in place. Again, for example, if the base is of a rectangular shape, then the continuous feature may extend continuously, defining a similar, but smaller rectangle surrounding by the continuous feature. For another example, if the base is of a square shape, then the continuous feature may extend continuously, defining a similar, but smaller square surrounding by the continuous feature.

In a further embodiment, there may be two groups of walls in that adjacent walls may include features that may be different. For example, the same interface features may be present on two edges of each of the walls of one group that is different than the interface features present on the other two edges of the walls of this group, while a complementary feature may be present on two of the edges of the walls of the other group. Again, each of the walls may include a rectangular or square outside surface, with a main platform portion being of the same configuration, but of a smaller rectangle or square than the dimension of the outside surface. Extending from the main platform portion of each of the walls of the first group may be a step edge on each of two edges of the walls, and an extension from the outside edge of each of the other two edges, the extension having a thickness and wraps at a substantially 90° angle about a portion of the inside edge, forming a channel therebetween the inside and outside surface. The wrapping portion may be of a shape that when assembled, gives the corners of the container a rounded, chamfered and/or otherwise smooth shaped edges such that sharp and/or pointed portions of the container may be minimized. Extending from the main platform portion of each of the walls of the second group may be a complementary feature on each of two edges of the walls for mating with the wrap features of the walls of the first group. The complementary features may be a step edge or any other complementary features. According to one embodiment, the feature of the base maybe the same as the feature of the top and different from those of any of the walls. In one aspect, the feature of the base and/or the top may be the same all around. In another aspect, the feature along one edge of the base and/or the top may be different from its adjacent neighboring edge. These different ones are usually also complementary to each other. In one embodiment of any of the aspects just described, the features along any one of edges of any of the walls may be the same for attaching to the base and the top, which are different from the features for attaching to another wall, i.e., the feature along one of the edges of any of the walls may be different from its adjacent neighboring edge and the same from its non-adjacent neighboring edge for all walls. In another embodiment of any of the aspects just described, the feature along one of the edges of any of the walls may be different from its adjacent neighboring edge and the same from its non-adjacent neighboring edge for all walls. In a further embodiment of any of the aspects just described, the features along one of the edges of the walls for attaching to adjacent walls are different from each other.

According to another embodiment, the features of the base maybe different from the features of the top and different from those of the walls. In one aspect, the feature of the base and/or top may be the same or similar all around. In another aspect, the feature along one edge of the base and/or the top may be different from its neighboring edge. In one embodiment of any of the aspects of the base just described, the feature along one of the edges of any of the walls may be different from all its adjacent neighboring edges and non-adjacent edges. In another embodiment of any of the aspects of the base just described, the feature along all the edges of any of the walls may be the same on the edges that connects to adjacent walls and different from the edge that connects to the base and to the top. In a further embodiment of any of the aspects just described, the features along the edges of any of the walls for attaching to adjacent walls are different from each other.

In one exemplary embodiment, an enclosure may be made up of a knock-down or collapsible container for storage and/or shipping, the knock-down or collapsible being of varying degrees, having a base, four walls extending therefrom and a top panel to form a closed enclosure therein, where the four walls are substantially similar in shape and feature identical interlocking features such that the container may have a minimum of three different components: a top panel, a base and interchangeable wall panels. The identical interlocking features on the wall panels may also generally aid in forming a rigid, resilient and easy to assemble/disassemble container. Each of the base, the walls and the top may include a main platform portion and an interlocking feature portion surrounding the main platform portion. The main platform portion of each of the components together defines the inside dimension of the container. The interchangeability also aid in manufacturing and inventory. For example, the interchangeability means fewer different parts need to be manufactured and inventoried.

The base and the top may include a top surface, a bottom surface, and a thickness joining the top surface and bottom surface. Cargo and/or other material may rest on the top surface of the base when the container is assembled. The cargo may be loaded before the walls of the container are assembled, or it may be loaded after the walls are assembled on the base. In some embodiments, the cargo may be loaded when top and some walls are assembled for side loading. The base may also generally include a plurality of supports, such as legs, which may extend from the bottom surface of the base. The supports may generally space the bottom surface of the base from the ground and/or other support surface. The supports may also be spaced from each other such that, for example, the base may be manipulated with a forklift and/or other moving machinery fitting into the spaces between the supports. Runners, bridges and/or other connectors may also be included, such as, for example, connecting multiple supports, which may generally increase the strength and/or rigidity of the base. The runners or bridges may be manufactured from any suitable material. For example, the bridges may be constructed from wood, metal and/or various plastics materials, including lead free PVC. In some embodiments, the runners or bridges are manufactured from HIPS (high impact polystyrene) using an extrusion forming process. Further, the bridges may be configured so that they each span two or more supports of a row and may be affixed to the ends of the supports so that they interconnect. For example, the bridges may be affixed using a suitable adhesive. In addition, the bottom of the supports for affixing the bridges may include indentations for retaining the bridges so that the bridges are not protruded from, but flushed with the bottom of the supports.

The bottom surface of the base and/or the supports may also include ridges, ribs, reinforcements and/or other surface modifications to which may, for example, aid in increasing the strength and/or rigidity of the structure of the base, especially under load. Some modifications also aid in reducing any unintended slippage of the container while at rest. In some aspects, the modifications may be roughening the bottom surface to reduce slippage. It is also believed that the ability of the supports and/or base to resist compressive loads is greatly enhanced if each of the side walls includes a plurality of generally longitudinally extending ribs.

The base and the top may generally include a main platform portion, an interface feature surrounding the main platform portion, and an outer edge portion surrounding the interface feature. In one aspect, the interface feature of the base and the top may include, for example, a circumferential groove or channel, with an outer edge surrounding the circumferential groove, which outer edge may be of substantially the same thickness as that of the platform portion. In another aspect, the interface feature of the base may include, for example, a circumferential groove or channel surrounding the main platform, with an outer edge surrounding the circumferential groove, and the interface feature of the top may include, for example, a circumferential ridge or protrusion surrounding the main platform, with an outer edge surrounding the circumferential ridge or protrusion, the outer edge being of substantially the same thickness as that of the platform portion. In a further aspect, the interface feature of the top may include, for example, a circumferential groove or channel surrounding the main platform, with an outer edge surrounding the circumferential groove, and the interface feature of the base may include, for example, a circumferential ridge or protrusion surrounding the main platform, with an outer edge surrounding the circumferential ridge or protrusion, the outer edges of both the top and bottom being of substantially the same thicknesses as that of the platform portions. In yet another aspect, the interface feature of the base and the top may include, for example, a circumferential ridge or protrusion, with an outer edge surrounding the circumferential ridge or protrusion, which outer edge may be of substantially the same thickness as that of the platform portion.

In one aspect, a portion of the walls may interface with the base and/or top by insertion into the circumferential groove of the base and/or top. A portion of the wall panels may also rest on the top surface of the circumferential edge surrounding the circumferential groove or channel, such that, for example, the wall panels and the base may interface with a minimal gap or space at base (or top) interface. The base or top may also feature rounded, chamfered and/or otherwise smooth shaped edges such that sharp and/or pointed portions of the container may be minimized. In another aspect, a portion of the walls may interface with the base and/or top by insertion of the circumferential protrusion or ridge of the base and/or top into the groove or channel of the wall. A portion of the wall panels may also rest on the top surface of the circumferential edge surrounding the circumferential ridge or protrusion, such that, for example, the wall panels and the base may interface with a minimal gap or space at base (or top) interface. The base may also feature rounded, chamfered and/or otherwise smooth shaped edges such that sharp and/or pointed portions of the container may be minimized.

The interfacing grooves, channels, protrusions, ridges, wrapping portions and/or corner interfaces may also generally act as tongue and groove interfaces, and may thus provide rigid and/or largely self-supporting connections between the components which may require minimal if any reinforcement when assembled. The interfaces may also generally resist loads in all directions.

In one aspect, the interlocking features mentioned above may also aid in assembly after the cargo is loaded, and/or aid in easy knock-down or partial knock-down of the continuer before the cargo is unloaded from the container. This is advantages especially if the cargo is not easily loaded or unloaded though an opening, such as the top or side. In another aspect, the interlocking features may also aid in the holding strength and integrity of the container without the use of buckles or straps or any metal reinforcing material, for example, to aid the container in withstanding any cargo that may weigh up to about 10 times, about 15 times or about 25 times the weight of the container, without giving way when the weight is evenly distributed inside the container, even when the walls may buckle or bulge.

The containers formed may even be stacked on top of each other. It is anticipated that at least two may be stacked on top of the bottom one, even when fully loaded with cargo.

In one embodiment, each of the walls, top and base of the container may be made of a light weight core substantially covered with a polymeric layer, for example, a high impact sheet or a coating on at least one of its surfaces to form a load bearing structure having a width or thickness as noted above. In another embodiment, a structural metal mesh may be inserted into the core to resist piercing of the surface. In a further embodiment, one or more of the walls, top and base portions may be made by injecting a polymer into a mold to form the core and after removing the core from the mold spraying a polymer coating on the polymer core. The interfacing features may be formed during any step of the manufacturing process. In one example, the features may be molded when the components are made. In another embodiment, the features may be forged into the components after the components are made. When forged after the components are made, the exposed surface of the core may either remain exposed or a spray coating made be added to cover the exposed surface of the core. In yet a further embodiment, for example, liquid polyurethane may be injected into a mold to form a polyurethane core containing grooves, channels, protrusions, ridges, extensions, wrapping portions and/or pockets which after curing is removed from the mold and sprayed with polyurea to form one or more of the load bearing structures having interfacing features. Using this molding process, size and shape may be easily varied. In yet another embodiment, any light weight core may be covered with a spray coating after forging all of the features, for example, any closed cell foam may be sprayed coated with a polyurea coating after interface features are forged. The effectiveness of the interlocking features may also be increased when the mating surfaces are roughened or higher frictional materials are used.

In another exemplary embodiment of the invention, the container includes two halves, and each of the halves may or may not include the top or the bottom components. The interfacing locking features on the components may include any or all combinations of those described above. In one embodiment of the invention, the container includes two identical or mirror images of substantially L-shaped cross-sectional halves each having at least two walls and a base or top component, each of the components having corresponding interlocking features to be mated together to form a container having for example, a closed enclosure therein. In this embodiment, one substantially L-shaped cross-sectional half may be integrally formed or joined with a top component, while another substantially L-shaped cross-sectional half may be integrally formed or joined with a bottom or base component such that the two may be assembled to form a complete enclosed container. In another embodiment, the container includes two identical or mirror images substantially L-shaped cross-sectional halves each having at least two wall components, each of the components having corresponding interlocking features to be mated together to form a container having for example, a closed enclosure therein when mated with the top and bottom components. For a container formed from two identical, substantially L-shaped cross-sectional halves, or walls, each half may be integrally formed or joined from two of the wall sections, as discussed above, with or without either a top or a bottom component. The wall sections may generally be identical or similar in shape and size, and though integrally formed or joined together, each still kept its distinct platform portion. In these embodiments, each half includes two vertical edges and two horizontal edges to interconnect with other components, for example, with each other and with the top and bottom portions to form the container.

In one aspect of any of the embodiments described above, each of the substantially L-shaped cross-sectional halves may include an inside surface, an outside surface, a thickness connecting the inside and outside surfaces, four outside edges and four inside edges, and at least two different interface features for the wall components.

In one embodiment, the same interface feature may be present on two of the edges, generally the edges that run either vertically or horizontally, of each of the halves, and a different interface feature present on the other two edges, which may be the same or different. Each of the halves may include two rectangular or square outside surfaces integrally formed or joined to each other, with each of the main platform portion being of the same geometry, but of a smaller rectangle or square than the dimension of the outside surface. Extending from the main platform portion of each of the two vertical free edges may be a step edge, and an extension from the outside edge of one of the other free edges, the extension having a thickness and wraps at a substantially 90° angle about a portion of the inside edge, forming a channel therebetween the inside and outside surface. The wrapping portion may be of a shape that when assembled, gives the corners of the container a rounded, chamfered and/or otherwise smooth shaped edges such that sharp and/or pointed portions of the container may be minimized.

In another embodiment, each of the substantially L-shaped cross-sectional halves may include an inside surface, an outside surface, a thickness connecting the inside and outside surfaces, four outside edges and four inside edges, and each of the walls that are integrally formed or joined to form the half may include a rectangular or square outside surface, with a main platform portion being of the same, but of a smaller rectangle or square than the dimension of the outside surface. The integrally formed L-shape halves noted here may include two walls, with the interlocking features being present at the free end of the L-shaped halves for connecting with identical or complementary L-shaped halves and top and bottom components. Extending from the main platform portion of each of the walls may be a step edge on two of the edges of the walls for mating with the base and top, a channel surrounding the main platform on one edge of the walls and an edge surrounding the channel, and an extension from the outside edge of the other edge of the walls, the extension having a thickness and wraps at a substantially 90° angle about a portion of the inside edge, forming a channel therebetween the inside and outside surface. The wrapping portion may be of a shape that when assembled, gives the corners of the container a rounded, chamfered and/or otherwise smooth shaped edges such that sharp and/or pointed portions of the container may be minimized. The step edge interface feature of one edge of the adjacent half mats to the channel formed and the wrapping portion secured the matting portions in place.

In a further embodiment of the invention, the container includes two halves, such as clam shell halves, in identical or mirror images, each having at least one wall and a base or top component, each of the components having corresponding interlocking features to be mated together to form a container having for example, a closed enclosure therein. Each of the halves having an inner surface and an outer surface joined by a width. The footprint of the knock-down or collapsed container is not larger than the footprint of each of the substantially L-shaped cross-sectional halves or clam shell halves.

In yet another embodiment of the invention, the container includes two halves, in identical or mirror images, each having at least one wall and two half walls with half the top component, each of the components having corresponding interlocking features to be mated together to form a container having for example, a closed enclosure therein. Each of the halves having an inner surface and an outer surface joined by a width. The footprint of the knock-down or collapsed container is not larger than the footprint of each of the halves.

According to one embodiment, each half is made of an inner light weight core covered by at least one layer of strengthened coating. According to another embodiment, a structural metal mesh may be inserted into the core to resist piercing of the surface. According to a further embodiment, one or more of the substantially L-shaped cross-sectional, or clam shell halves may be made by injecting a polymer into a mold to form the core and after removing the core from the mold, spraying a polymer coating on the polymer core. For example, liquid polyurethane may be injected into a mold to form a polyurethane core containing grooves, protrusions and/or pockets which after curing may be removed from the mold and sprayed with polyurea to form one or more of the load bearing structure and the half enclosures. The interlocking features may include respective depression and protrusion features on adjacent connecting components.

For the integrally formed L-shaped halves that may include two walls and either a top or bottom components, with the interlocking features being present at the free ends for connecting with complementary clam shell or L-shaped halves, the interlocking features are again as mentioned above, with the added advantage that fewer steps in assembling results while again with the advantage for easy loading especially if the cargo is not easily loaded or unloaded though an opening, such as the top or side alone.

In one aspect of any of the above mentioned embodiments, the container may be amenable to hold loads of up to, for example, about 15 times the weight of the container itself; more for example, up to about 20 times the weight of the container itself; and even more for example, up to about 25 times the weight of the container itself when the weight is evenly distributed inside the container. With the load pressing against the walls and base, the container remained intact without collapsing. In some instances, the container may buckle or bulge to an extent, but still remains intact.

In one aspect of any of the above embodiments, the container may have one or more thermal insulating agents to afford thermal insulating properties. In another aspect of any of the above embodiments, the container may have one or more antimicrobial agents to afford antimicrobial properties. The antimicrobial agents may be present on any exposed surfaces of the containers and/or any additional structures. In a further aspect, the container may have a combination of any thermal insulating and antimicrobial properties.

In any of the embodiments, the antimicrobial properties, if present, may be generated from materials including chemical anti-microbial materials or compounds that are capable of being substantially permanently bonded, at least for a period such as the useful life of the load bearing structures, either when at least one antimicrobial agent is added to the material used for making the polymeric layer, for example, a sheet or sprayed coating mentioned above, or when at least one antimicrobial agent having some surface activity is coated onto the exposed surface of the polymeric layer, for example, sheet or sprayed coating mentioned above; or maintain their anti-microbial effects when at least one antimicrobial agent is coated with the aid of coating agents, onto the exposed surface of the polymeric layer, for example, sheet or sprayed coating mentioned above. In one example, the chemicals may be deposited on the surface of the load bearing structures by covalent linkage.

According to one embodiment, the container may include an enclosure having one undivided internal compartment. According to another embodiment, the container may include an enclosure having more than one internal compartments. In one aspect, the interior may have dividers molded into the side of the component structures. In another aspect, the dividers may be added to the container to form separate compartments. Channels or depressions may be present or molded into the components of the container to allow for placement of external dividers to adjust the size of the compartments.

The inside of the platform area of the container may include features for locking or positioning the cargo in place to keep the cargo from shifting or moving during transport. Some interlocking characteristics may also be defined as a depression or protrusion in an inside wall surface of a container corresponding to a protrusion or depression in the cargo such that the container ‘mates’ with the cargo without requiring a fastener. According to one embodiment, features may be present or molded into the components of the container for placement of cargo or placement of other components for more secure location of cargo. According to another embodiment, the channels or depressions mentioned above may be used to locate the features.

In one aspect, the containers may be made of the size and shape to accommodate the cargo. In another aspect, the cargo may be contained in its own packaging and then inserted into the container. In a further aspect, features may be located in the container to aid in accommodating the cargo. In an additional aspect, features may be located in the container for use with the cargo.

In one aspect, the containers of the present invention are amenable for use in shipping and/or storage of cargo in which the climate within the container is controlled.

In an exemplary embodiment of the invention, cargo being shipped or stored may be damaged by exposure to temperatures that are too low or too high. It may be desirable to keep the cargo cool when being shipped and/or stored in a hot climate. It may also be desirable to keep the cargo warm when being shipped and/or stored in a cool climate. The temperature change may be due not only to location, but also due to the time of day, for example, the difference between night and day, or early morning and mid-day or afternoon. In an embodiment of the invention, the cargo container may include materials to provide climate control, for example, gaseous, solid or liquid materials which may cool, melt or becomes gaseous or phase change to control the temperature. In an embodiment of the invention, phase change material(s) are included in the cargo container to keep the contents cool in a hot climate. In an embodiment of the invention, phase change material(s) are included in the cargo container to keep the contents warm in a cool climate. Examples of cargos requiring climate control include food, pharmaceuticals, prescription and ‘off-label’ drugs, electronics equipment, computer parts, batteries and other articles that include chemicals that are temperature sensitive.

In another exemplary embodiment of the invention, where the contents of shipments or storage need to be kept above a certain temperature range, for example, above freezing, the shipping or storage container may include materials to provide climate control. For example, gaseous, solid or liquid materials which may liquefy, solidify or phase change may be included in the cargo container to keep the contents warm or from getting too cold. This may happen if materials are to be shipped over, a rail system, for example the trans-Siberian railroad. Examples of contents requiring climate control may include energy storage devices, batteries, electronics, computer parts, electronic circuits, memory storage devices, electronic chips, food stuff, pharmaceuticals and any other articles that need to be kept form getting too cold.

In an embodiment of the invention, the container may also be capable of recycling to changes of temperature. In an embodiment of the invention, the container may also be capable of responding to multiple changes of temperature. For example, the container may be capable of recycling from cold to warm and from warm to cold. Alternatively, the container may be capable of changing from hot to warm and from warm to cold.

In an embodiment of the invention, a cargo container is disclosed that is light weight, strong, made of insulating thermoplastic polymers and containing phase change materials to protect the cargo from extremes in temperature. In another embodiment of the invention, a cargo container is disclosed that is light weight, strong, made of insulating thermoplastic polymers and containing phase change materials to protect the cargo from temperatures between, for example, −2° C. and −50° C.

In another embodiment of the invention, a cargo container is disclosed that is light weight, strong, made of insulating thermoplastic polymers and containing phase change materials to protect the cargo from temperatures between 30° C. and 50° C.

In a different embodiment of the invention, a cargo container is disclosed that is light weight, strong, made of insulating thermoplastic polymers and containing phase change materials to protect the cargo from temperatures between −5° C. and 40° C.

Phase change materials or combinations of different phase change materials may be suitable for protecting a cargo in a limited confined space over broad ranges of temperatures. A phase change material (PCM), is a substance generally having a high heat of fusion, i.e., when converting from a solid phase to a liquid phase or when converting from a liquid phase to a solid phase at a certain temperature, the PCM may store or release large amounts of energy. The energy released may be in the form of heat absorbed or released. Thus, the PCM may release heat when the material changes from solid to liquid phase in order to keep the interior of the cargo container above the outside ambient temperature.

Latent heat storage may be achieved through solid-solid, solid-liquid, solid-gas and liquid-gas phase change. A substance exhibiting solid-liquid phase change may be convenient and easy to manage. Liquid-gas phase changes may have a higher heat of transformation than solid-liquid transitions. Typically, liquid-gas phase change transitions are less practical for use as thermal storage devices as large volumes or high pressures may be required to store the materials. However, when used with cargo containers the volume constraint may be less relevant. Solid-solid phase changes, such as, for example, changes from one solid crystalline lattice structure to another, are typically very slow and may also have a rather low heat of transformation.

For shipment or storage of materials that need to be kept cool during shipping, the solid-liquid PCMs are suitable heat storage materials. As the temperature rises, they absorb heat and when their temperature reaches the temperature at which the change phase occurs (their melting temperature) they absorb large amounts of heat at an almost constant temperature. This process continues without a significant rise in temperature until all the material is transformed to the liquid phase. When the ambient temperature around a liquid material falls, the PCM solidifies, releasing its stored latent heat. Thus, the PCMs not only help to keep the contents of any storage or shipment cool, but may also help to keep the contents from falling below a certain temperature. Thus, PCMs may self-recycle for an almost infinite number of cycles and are advantageous for shipments that may encounter numerous temperature cycles. Some of the phase change materials may undergo phase changes for an almost infinite number of times. Others may be more endothermic agents and thus may have a limited life cycle unless handled under a controlled environment. These endothermic agents may lose their effectiveness as a phase change material even when handled under a controlled environment. In an embodiment of the present invention, even the limited life cycle PCM may be useful for cargo containers.

There are numerous PCMs available in a required temperature range from −5° C. up to 190° C. that may be useful. Within the most common range of 20° C. to 30° C., some PCMs are very effective heat storage devices as they may store 5 to 14 times more heat per unit volume than conventional storage materials such as water, masonry or rock.

Phase change materials with different characteristics may also be used in the same cargo container to handle different temperature zone changes while shipping over a long distance. For example, a first phase change material may change phase around freezing temperature while a second phase change material may change phase below freezing temperatures. The container may also include a third phase change material that may change phase above freezing temperature.

The advantages of using PCMs for the present applications are that one may pack into the cargo container PCMs for any temperature requirement needed at various times without any concern that one material will interfere with the function of another. Thus, customization of energy control and temperature regulation is possible.

The phase change materials may be contained or packed in separate containers, for example, flexible or non-flexible plastic containers or pouches, or metalized containers or pouches, or combinations thereof. The containers may be of any shape and size. Metalized containers may be made of metal or made of plastic containers having metallic coatings for better heat conduction. When used in air freight and if facilitating security check of air cargo transport of cargo is desirable, containers that are transparent to magnetic scanners, such as non-metal containers, may be used, as further discussed below.

As phase change materials often perform better in smaller containers, the container may be further divided into cells or separate smaller containers may be desirable. The cells may be shallow to reduce static head based on the principle of shallow container geometry. That is, the cells may be shallow to minimize pressure exerted by the PCM. The packaging material may be chosen to be an excellent conductor of heat. The packaging material may be durable enough to withstand frequent changes in the PCM volume as phase changes occur. The packaging material may restrict the passage of water through the walls, so the materials will not dry out (or water-out, if the material is hygroscopic) and to resist leakage and corrosion. Common packaging materials showing chemical compatibility with room temperature PCMs include stainless steel, metalized films, polypropylene, polyethylene, and other polyolefins, polyesters, combinations and other similar materials to be discussed below. As mentioned above, when used in facilitating security check of air cargo transport of cargo that is transparent to magnetic scanners, non-metal containers may be used.

The pouches may generally be made of impervious materials, which may include commonly known polymeric materials including polyolefins, such as polyethylene, polypropylene, amorphous polyolefins such as Vestoplast 703® (Huls), metallocene polyolefins, and the like.

These containers or pouches of phase change materials may be placed in various places in the cargo container, including the base, top and side walls. They may even be placed in contact with or in close proximity to the cargo item to be protected from temperature changes, inside their packaging, similar to desiccant pouches. The phase change materials in their own packaging may also be arranged in layers. For example, flat, thin pouches may be stacked one on top of another or side by side. The pouches may have PCMs with same or different temperature properties. Thus, the phase change may occur in stages to provide custom protection for the contents being shipped or stored.

In an embodiment of the present invention, PCMs may be incorporated into the cargo container during construction of the container. In an alternative embodiment of the present invention, PCMs may be incorporated into the container during assembly of the parts of the cargo container.

In an embodiment of the present invention, customized temperature control may be possible with phase change materials when heat may be absorbed from, or released to, keep the contents of the cargo container within a specified range during transportation.

The cargo containers may be of square, rectangular, polygonal or clam shell shape. The parts forming the container may include a core and a layer of film or other applied coating material covering the core, as discussed above.

In an embodiment of the present invention, the contents may be surrounded by traditional insulating materials. In another embodiment of the present invention, the outside of the cargo container may be sealed to isolate the cargo container from the outside atmosphere. In a different embodiment of the present invention, styrofoam may be packed around the outside of the container prior to sealing the cargo container. In a further embodiment of the present invention, two or more enclosures may be used to insulate the container interior with additional PCMs inside each enclosure.

In one exemplary embodiment, at least one antimicrobial agent having some surface activity may be added to the material used for making the polymeric layer, for example, a high impact polymeric sheet. The antimicrobial agent may be in powder form or in liquid form. In another exemplary embodiment, at least one antimicrobial agent having some surface activity may be coated onto the exposed surface or surfaces of the sheet. The antimicrobial agent may be in powder form or in liquid form.

In a further aspect, the containers of the present invention are amenable for use in clean rooms for the manufacturing of electronic parts, snacks, food products or similar products that have to be kept clean from dust, dirt or microbes. The products are placed directly on the structure after having been made, thus eliminating steps, saving time, minimizing manpower or robotics, and/or risk of contamination or damage.

In yet another aspect, the containers of the present invention are amenable for use in facilitating security check of air freight cargo for shipping at the airport. The scanners for security may include electromagnetic inspection scanners. These scanners are designed for metal detection.

In still a further aspect, the containers of the present invention are amenable for use in situation where a combination of one or more of the properties is desirable.

Other embodiments of the cargo container and methods for its use, within the spirit and scope of the invention, may be understood by a review of the specification, the claims, and the figures.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A shows a line drawing of a cargo carrier dunnage platform with pockets for locating phase change materials and FIG. 1B a line drawing of a profile, according to an embodiment of the invention;

FIG. 2 shows a line drawing of the underneath side of the cargo carrier dunnage platform 2A with legs protruding and 2B in profile, according to an embodiment of the invention;

FIG. 3 shows a line drawing of the empty cargo carrier dunnage platform with a half enclosure positioned on the cargo carrier dunnage platform, according to an embodiment of the invention;

FIG. 3A shows a line drawing of a cargo carrier dunnage platform with phase change material containers positioned in pockets;

FIG. 4 shows a line drawing of the loaded cargo carrier dunnage platform with a half enclosure positioned on the cargo carrier dunnage platform, according to an embodiment of the invention; and

FIG. 5A shows a line drawing of a fully enclosed cargo carrier dunnage platform with the enclosure positioned on the cargo carrier dunnage platform, according to an embodiment of the invention.

FIG. 6 shows an L-shaped half of an embodiment of the container having features for locating cargo or partitions;

FIG. 6A show a full view of the inside bottom of an embodiment of the container of the present invention having features for locating cargo or partitions;

FIG. 7 shows fully assembled container of an embodiment of the present invention;

FIG. 7A shows an L-shaped half of an embodiment of the container having features for locating cargo;

FIGS. 8, 8A, 8B, 8C, 8D and 8E show another embodiment of a container of the present invention in various stages of assembly, depicting the interconnecting features;

FIG. 9 shows a line drawing of the empty cargo carrier dunnage platform with a half enclosure positioned on the cargo carrier dunnage platform, according to another embodiment of the invention;

FIGS. 10, and 10A show the embodiment of the present invention with an additional enclosure in various stages of being installed;

FIGS. 11 and 11A illustrate an embodiment of a container with tongue and groove interfaces;

FIGS. 12 and 12A illustrate a base of the container of FIGS. 11 and 11A;

FIGS. 13, 13A and 13E illustrate a wall panel of the container of FIGS. 11 and 11A;

FIGS. 13B, 13C and 13D illustrate a wall panel interfacing with a top panel, another wall panel and a base, respectively;

FIGS. 14 and 14A illustrate a top panel of the container of FIG. 11;

FIG. 15 illustrates the assembly of the container of FIG. 11;

FIGS. 16, 16A, 16B, 16C, 16D and 16E illustrate embodiments of bases with different legs and supports;

FIGS. 17, 17A and 17B illustrate integrally formed or joined wall panels in a substantially L-shaped configuration for interfacing with a top panel and a base; and

FIGS. 18, 18A and 18B illustrate a pair of integrally formed or joined wall panels in a substantially L-shaped configuration, one of which is integrally formed or joined with a top panel and the other of which is integrally formed or joined with a base.

DETAILED DESCRIPTION OF THE INVENTION

The detailed description set forth below is intended as a description of the presently exemplified embodiments of the present invention and is not intended to represent the only forms in which the present invention may be prepared or utilized. The description sets forth the features and the steps for practicing the present invention. However, it is to be understood that the same or equivalent functions and components may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices and materials similar or equivalent to those described herein may be used in the practice or testing of the invention, the exemplified methods, devices and materials are now described.

All publications mentioned herein are incorporated herein by reference for the purpose of describing and disclosing, for example, the designs and methodologies that are described in the publications which might be used in connection with the presently described invention. The publications listed or discussed above, below and throughout the text are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the inventors are not entitled to antedate such disclosure by virtue of prior invention.

A load bearing structure is an article or structure designed to store or transports a load and may include a dunnage platform or pallet.

An enclosure is an article or structure designed to enclose a cargo loaded onto a load bearing structure so that the cargo container interior may be isolated from the cargo container exterior. The enclosure may be made up of two half enclosures (as in clam shells or similar), or multiple components, as shown in FIG. 3 or 6, or multiple panels such as multiple dunnage platforms, as shown in FIG. 8C.

The containers may be suitable for storage or transporting of food, pharmaceuticals, prescription and off label drugs, electronics, equipment, computer parts, batteries and other articles that include chemicals that are or are not temperature sensitive.

The containers may be suitable for storage or transport of materials where eliminating, preventing, retarding or minimizing the growth of microbes and also minimizing cross-contamination when the structure is being reused for cargos that are different from previous cargo, for example, different food types, such as poultry, fresh vegetables, and fresh fruits are desirable.

The container may be suitable for storage or transport of cargo that may weigh up to, for example, about 15 times the weight of the container itself; more for example, up to about 20 times the weight of the container itself; and more for example, up to about 25 times the weight of the container itself when the weight of the cargo is evenly distributed inside the container.

The enclosure may be an undivided compartment, as shown in FIG. 8, or may be divided into multiple compartments (not specifically shown), each compartment may be suitable for storage or transport of cargos with different characteristics. In one aspect, one compartment may have climate control while the rest of the compartment may not. In another aspect, one compartment may be padded for extra shock protection while the rest may not. In yet another aspect, a compartment may be sized for a specific article while another compartment may be sized for a different article. In general, any of the exposed surfaces may have anti-microbial properties.

Approximately when used with temperatures expressed to one significant figure can include a range between + and − two (2) degrees. Approximately when used with temperatures expressed to two significant figures can include a range between + and − five (5) degrees. Approximately when used with specific heats expressed to two significant figures can include a range between + and − zero point two (0.2).

Climate control is used to describe the use of chemical and/or physical properties of substances to alter the atmosphere inside the cargo container relative to the atmosphere outside the cargo container.

In an embodiment of the invention, the cargo container may be a modular, lightweight, strong container that may include any or all of the properties stated below: ultra violet light insulating, tamper resistant, receptacle for insulating, preserving, facilitating security check, or tracking and transporting cargo. In an embodiment of the invention, the cargo container may be a modular, lightweight, strong, ultra violet light insulating, tamper resistant load bearing structure with enclosure for insulating, preserving, tracking and transporting cargo. In yet another embodiment of the invention, the cargo container is a modular, lightweight, strong, container that may be ultra violet light insulating, tamper resistant dunnage platform with enclosure for insulating, preserving, tracking and transporting cargo. These cargo containers may include two halves or plurality of dunnage platforms or load bearing structures, as shown in the figures, for example, FIGS. 3, 6 and 9, 11, 11A, and 15.

In a further embodiment, the cargo container is a modular, lightweight, strong, container that may be used for facilitating security check of air freight cargo for shipping at the airport.

FIGS. 1-5 depict an embodiment of the cargo carrier in which a dunnage platform with pockets for locating phase change materials that may be integrally attached to an enclosure to seal and preserve the cargo. The cargo carrier dunnage platform with phase change material containers 125A positioned in pockets 125 and a half enclosure positioned on the cargo carrier dunnage platform 100, as shown in FIGS. 3 and 3A, are examples of an embodiment of the invention. As mentioned above, though not specifically shown, the container may be constructed without pockets for phase change material.

In FIGS. 1A and B, a dunnage platform 100 is shown, (or one without pockets is not specifically shown here) are shown to be used as a base with a top surface 115 and edges 110. The top surface 115 is used to denote both a polymeric layer or sheet or just the top surface of the core without a polymeric layer or sheet. The base or dunnage platform 100 shown in FIG. 1A has six (6) pockets 125 and two (2) grooves or recesses 130 penetrating the top surface 115, each of which may extend into the core (not shown) of the base or dunnage platform. In an embodiment of the invention, the pockets 125 may be used to locate phase change materials. In an embodiment of the invention, the grooves or recesses 130 are used to locate one or more enclosures. In FIG. 1B the profile of the dunnage platform 100 is shown where legs 145, 150 and 155 extend from the bottom surface 170 of the dunnage platform 100. In FIG. 2A the underneath of the dunnage platform 100 is shown where legs 145, 150, 155, 240, 245, 250, 255, 260 and 265 extend from the bottom surface 170 and together with the edge of dunnage platform 110 make up the height of the dunnage platform 100.

The load bearing structures may include a plurality of bridges or reinforcement members that may be affixed to the second side of at least some of the legs of all of the embodiments of load bearing structures described herein, for example, as shown in FIGS. 16A, 16B and 16C, to be described in more details below. For reinforcing members or bridges, they can either be flushed with the bottom of the supports, protruding from the bottom of the supports or neither protruding from or flushed with the bottom of the supports.

The load bearing structures may also include a plurality of wear resistant members that may be affixed to the second side of at least some of the legs of all of the embodiments of load bearing structures described herein. Details of the wear resistant members may be found in U.S. Pat. Nos. 7,908,979, and 5,868,080, the contents of all of which are hereby incorporated by reference in their entirety. Thus, for wear resistant members, they are protruding from the bottom of the supports.

These wear resistant members may be similar to bridges or reinforcing members that extend between adjacent legs. In some embodiments, only one of these members may be present. In other embodiments, two of these may be arranged in the shape of a cross, for example, as shown in FIG. 16A. In further embodiments, one of each may be attached to each pair of adjacent legs around the peripheral of the load bearing structure, for example, as shown in FIG. 16C. In still other embodiments, they may be attached to every pair of legs of the load bearing structure.

In FIG. 2B the profile of the dunnage platform 100 is shown where legs 145, 150 and 155 extend from the bottom surface 170 of the dunnage platform 100.

FIGS. 3 and 3A show an embodiment of a substantially L-shape half having interlocking features for mating with another identical, substantially L-shaped half having complementary interlocking features to form a container in an embodiment of the present invention. As shown in FIGS. 3 and 3A, the substantially L-shape cross-sectional half may or may not include the base and may include one, two or three wall components, some of the wall components and the top component are half walls or half top components. This embodiment may or may not have pockets for phase change materials.

In FIG. 3 a first half enclosure 380 is located on the dunnage platform using the groove or recess 130, where the pockets for locating the phase change material 125 are located interior to the first half enclosure 380. The half enclosure 380 has a corresponding feature to mate with the groove or recess 130. FIG. 3 a shows an embodiment of FIG. 3 with phase change material packets 125 a inside the pockets 125.

The cargo carrier dunnage platform with phase change material containers 125A positioned in pockets 125 and a half enclosure positioned on the cargo carrier dunnage platform, is an embodiment of the invention. These containers or pouches are shown here in substantially rectangular form, but they may be in other forms. Also, the pouches may be located in other locations inside the cargo container including in contact or in close proximity to the cargo item to be protected from temperature changes, or inside the packaging of the cargo item, similar to placement of desiccant pouches. As mentioned before, the thinner and/or smaller the pouches for containing phase change materials, the better the effects exhibited by the phase change materials.

FIG. 4 shows the cargo 490 loaded on the dunnage platform with the first half enclosure 380 located using the groove or recess 130. The cargo 490 loaded on the dunnage platform with the first half enclosure 380 located using the groove or recess 130.

In FIG. 5A the cargo is enclosed using a second half enclosure 380 located on the dunnage platform using the groove or recess 130 to form the cargo container 500. In an embodiment of the invention, the first half enclosure and the second half enclosure are identical and may be interchanged by rotating by 180° around a central axis perpendicular to the plane of the dunnage platform and are therefore described as symmetrical.

In various embodiments of the invention described above or below, a cargo carrier 100 includes an enclosure with pockets 125 for locating phase change materials which is integrally attached to a dunnage platform 100. In an embodiment of the invention, the dimensions of the dunnage platform 100 may be approximately 1319 mm×1116 mm×165 mm, for ease of use with conventional lifting equipment. In an embodiment of the invention, the exterior dimensions of the enclosure may be approximately 380, 583 are 1319 mm×1116 mm×1574 mm. In an embodiment of the invention, the interior dimensions of the enclosure may be approximately 380, 583 may be approximately 1219 mm×1016 mm×1524 mm. In various embodiments of the invention, it will be understood by persons having skill in the art that the use of the term ‘approximately’ when used together with dimensions that indicate a range may vary by up to 50% of the range and the above measurements are only given as an example. Many other dimensions for custom-fitting cargo items may be used.

In an embodiment of the invention, a corresponding protrusion (not specifically shown here, but similar to 841 in FIG. 8 b) extending from a first or a second enclosure 380, 585, as shown in FIG. 5A, may be inserted into a groove or recess 130 in a dunnage platform surface 115 (as shown in FIG. 1A) to locate the enclosure 380, 585 on the dunnage platform 100. In an embodiment of the invention, a clasp (not shown) may be used to insure the integrity of the connection between the first and second enclosure 380, 585. In an embodiment of the invention the groove or recess 130 may be approximately 902 mm×32 mm×20 mm. In an embodiment of the invention, a mesh, a sheet or a barrier associated with a protrusion may be inserted in the groove or recess of the dunnage platform 130 and a key may pass through a hole in the dunnage platform core (not shown) to lock and/or retain the enclosure 380, 585 onto the dunnage platform 100. In an embodiment of the invention, the protrusion may pass thru a mesh, a sheet or a barrier inserted in the core of the dunnage platform and a key may pass through a hole in the dunnage platform core (not shown) to lock and/or retain the enclosure 380, 585 on the dunnage platform 100. In an embodiment of the invention, a clasp may be fixed on the outside of the enclosure or connect with straps encircling the cargo container. In one embodiment of the invention, the clasp may connect with a mesh, a sheet or a barrier inserted in the core of the first or second enclosure 380, 585. The clasp may then be fixed on the outside of the second or first enclosure 585, 380 or connect with straps encircling the cargo container.

According to one embodiment, the container 500, 600 or 800 may include an enclosure having one undivided internal compartment, as shown in FIG. 3, 6, 8C or 8E. According to another embodiment, the container 500, 600 or 800, may include an enclosure having more than one internal compartment, not specifically shown. In one aspect, the interior may have dividers molded into the side of the component structures (not specifically shown). In another aspect, the dividers may be added to the container 500, 600 or 800 to form separate compartments. Features 612 or 622, as shown in FIGS. 6, 6A and 7A, may be present or molded into the components of the container 600 to allow for placement of dividers to adjust the size of the compartments.

FIGS. 6, 6A and 7 show embodiments of an L-shaped half of a container 600, which may generally have, for example, a substantially L-shaped cross-section, having a channel or groove, 130, molded or formed on the various sides. Slots 612 or 622 are molded or formed on the interior of all side, base or top components, 610 or 620 of FIGS. 6, 6A and 7A, for attaching dividers (not shown) to create various compartments inside the enclosure, or for attaching shaped features 700 for resting cargo, as shown in FIG. 7A. In one embodiment, the slots 612 or 622, may be formed or molded in fixed distance apart, as shown in FIGS. 6, 6A and 7A, so that same size or multiples of one size compartments may be formed. In another embodiment, slots 612 or 622 may be formed or molded in varied distance apart (not specifically shown), so that different size compartments may be formed which may or may not be multiples of one size. In one aspect, the slots 612 or 622 are formed at corresponding positions on the inside surfaces of the side, top or bottom components to form compartments that are either substantially parallel to the horizontal or vertical. In another aspect, the slots 612 or 622 are formed at an angle with respect to the horizontal or vertical. These slots may be used to locate cargo items to be protected from temperature changes inside their own packaging and may include pouches of PCMs in contact or in close proximity with cargo items.

According to one embodiment, features 700 may be formed or molded into the components of the container, 500, 600 or 800, as shown in FIGS. 5A, 7 and 8, for placement of cargo or placement of other components for more secure location of cargo. For multi-compartment containers 500, 600 or 800, the phase change material may be present in one or more of the compartments in the shipping container 500, 600 or 800, or it may be present with the cargo and the container 500, 600 or 800.

The containers 500, 600 or 800, as shown in FIGS. 5A, 7 and 8, may also be made of the size and shape to accommodate the cargo, or the cargo may be contained in its own packaging and then inserted into the container 380 or 600, as shown in FIGS. 4 and 6, as noted above.

FIG. 7 shows a closed container 600 by mating two substantially L-shaped cross-sectional halves, such as that shown in FIG. 6 or 7A, similar to FIG. 5. The substantially L-shaped cross-sectional halves may be mirror images or may be identical if turned 180°, as noted above.

In one embodiment, the enclosure may also be made up of a knock down or collapsible container 800 for storage and/or shipping, as also in FIG. 8, having a base, four walls extending therefrom and a top panel to form an enclosure therein, each of which having an inside surface, an outside surface, a width joining the inside and outside surfaces, and four inside edges and four outside edges, as shown in FIG. 8D.

FIG. 8 illustrates a perspective view of an assembled container 800 which may generally include a base 812, side pieces 801, 802, 803 and 804, and a top 816. In general, the container 800 may be assembled into the form illustrated in FIG. 8 without the use of adhesives, fasteners and/or other assembly aids and may substantially assemble in a predetermined fashion and retain the illustrated form. In one embodiment, as shown in FIG. 8A, the base 812 may generally be rectangular and may include a plurality of channels or grooves 831, 832, 833 and 834, each adjacent to an edge of the base 812. The grooves 831, 832, 833 and 834 may each terminate at a corner which is substantially open to the edge, as shown with corners 812 a, b, c and d, such that the grooves are open at least one end to insert a side piece. The corners 812 a, b, c and d may also include a closed edge which may thus act as a stop such that, for example, a side piece(s) may abut against the closed edge of the corner and be substantially retained and prevented from advancing beyond the corner. As illustrated in FIG. 8B, a side piece, such as side piece 801, may include a corresponding ridge 841, which may slide into and be retained in a corresponding groove, such as groove 831 as illustrated. The side pieces, such as illustrated with side piece 801, may further include a ridge 841 a opposite ridge 841 which may correspond and be retained in a corresponding groove of the top 816.

In general, the side pieces 801, 802, 803 and 804 may include edges orthogonal to ridges which correspond to the grooves of the top 816 and base 812, as illustrated in the top view of the container 800 in FIG. 8C. In general, the orthogonal edges may mate to each other with interlocking connections, as illustrated with connections 853, 854 and 855. In general, to assemble the container 800, for example, the side piece 804 may be inserted into the groove 834, followed by side piece 803 in groove 833, side piece 802 in groove 832 and then side piece 801 in groove 831. Side pieces 801 and 802 may include a non-interlocking junction, as illustrated with abutting edges 851 and 852, such that side piece 801 may be inserted without interference from a protruding piece. The top 816 as illustrated in FIG. 8D, which may include grooves 833 a, b, c and d, which may correspond to ridges 842 a, b, c and d of the side pieces, respectively, may then be placed such that the corresponding ridges fit into the grooves of the top 816, closing the container 800. The top 816 may also, for example, be placed before all of the side pieces are placed, such as illustrated in FIG. 8E. The side pieces, such as side piece 801 as illustrated in FIG. 8E, may also include handling features, such as the handle depressions 801 d, such that the side pieces may be manipulated with greater ease.

The containers 800 of FIGS. 8, 8A-E may also have formed or molded on the interior of all side, base or top components, slots, such as 610 or 620 of FIGS. 6, 6A and 7A, for attaching dividers (not shown) to create various compartments inside the enclosure, or for attaching shaped features 700 for resting cargo, such as shown in FIG. 7A. The slots 612 or 622, may be formed molded in fixed distance apart, such as shown in FIGS. 6, 6A and 7A, so that same size or multiples of one size compartments may be formed; or they may be formed or molded in varied distances apart (not specifically shown), so that different size compartments may be formed which may or may not be the multiples of one size.

According to one embodiment, features 700 may be also formed or molded into the components of the container 800 of FIGS. 8, 8A-E, for placement of cargo or placement of other components for more secure location of cargo.

Also, the containers 800 may be made of the size and shape to accommodate the cargo, or the cargo may be contained in its own packaging and then inserted into the container 800.

Though not specifically shown, the container embodiments of FIGS. 6, 6A, 7A, 8, 8A-E may also have a base component having features such as 125, as shown in FIGS. 3A and B, for locating phase change materials, as discussed above.

In some embodiments, the enclosure may also be made up of a knock down or collapsible container 200 for storage and/or shipping, as illustrated in FIG. 11, having a base, four walls extending therefrom and a top panel to form an enclosure therein, where the four walls are substantially similar in shape and feature identical interlocking features such that the container 200 may have a minimum of three different components: a top panel, a base and a wall panel. The identical interlocking features on the wall panels may also generally aid in forming a rigid, resilient and easy to assemble/disassemble container 200.

FIG. 11 illustrates a perspective view of a container 200 which may include a top panel 210, four wall panels 220 and a base 230. The wall panels 220 may generally join to each other at side interfaces 204 to form a substantially rectangular enclosure with a space 201 as shown in FIG. 11A, which in turn may join with the base 230 at base interface 206 and with the top panel 210 at top interface 202.

In general, the base 230, as illustrated in FIGS. 12 and 12A, may include a main platform 232 on which cargo and/or other material may rest when the container 200 is assembled. As noted above, the main platform portions of all the components define the inner space of the container 200 when assembled. The base 230 may also generally include a plurality of supports, such as legs 238, which may extend from the bottom surface 231, as shown in FIG. 12A. At the base interface 206 with the wall panels 220, the base 230 may generally include an interface feature, such as the circumferential groove 236 between the main platform 232 and an outer circumferential ring or edge portion 234, as shown in FIG. 12. In general, a portion of the wall panels 220 may interface with the base 230 by insertion into the circumferential groove 236. A portion of the wall panels 220 may also rest on the top surface 235 of the circumferential ring 234, such that, for example, the wall panels 220 and the base 230 may interface with a minimal gap or space at base interface 206. The base 230 may also feature rounded, chamfered and/or otherwise smooth shaped edges such that sharp and/or pointed portions of the container 200 may be minimized, such as with chamfered edge 237 and rounded corners 239 of the circumferential ring 234, and with rounded corners 233 of the main platform 232, as illustrated in FIG. 12.

In general, the top panel 210, as illustrated in FIGS. 14 and 14A, may include a main platform portion 212 which may form the roof when the container 200 is assembled, and an outer surface 211. At the top interface 202 with the wall panels 220, the top panel 210 may generally include an interface feature, such as the circumferential groove 216 between the inner main platform portion 212 and an outer circumferential ring 214, as shown in FIG. 14A. In general, a portion of the wall panels 220 may interface with the top panel 210 by insertion into the circumferential groove 216. A portion of the wall panels 220 may also rest on the bottom surface 215 of the circumferential ring 214, such that, for example, the wall panels 220 and the top panel 210 may interface with a minimal gap or space at base interface 202. The top panel 210 may also feature rounded, chamfered and/or otherwise shaped edges such that sharp and/or pointed portions of the container 200 may be minimized, such as with chamfered edge 217 and rounded corners 219 of the circumferential ring 234, and with rounded corners 213 of the main platform portion 212, as illustrated in FIGS. 14 and 14A.

Each of the wall panels 220 may generally include a rectangular panel 222 with four edges with interfacing features. In some embodiments, three of the four edges may be formed as stepped edges with a portion of the overall thickness of the rectangular panel 222 extending outward, such as to form a partially circumferential step, such as illustrated in FIGS. 13 and 13E with the stepped edges 226 a, 226 b, and 226 c forming step 226. The fourth edge may be formed as a wrap-around extension, such as illustrated with the extension 224 with a portion of the overall thickness of the rectangular panel 222 in FIGS. 13 and 13A, that extends out from the edge 223 and wraps at a substantially 90° angle to the plane of the rectangular panel 222 towards the inner surface 228 of the rectangular panel 222, which may generally form a channel or groove between the wrap-around portion of the extension 224 and the unextended edge 223 a of the rectangular panel 222, such as the groove 225 as illustrated in FIGS. 13 and 13A.

The stepped edges 226 a, 226 b, and 226 c may generally be shaped to fit into grooves of other components of the container 200, such as, for example, the edge 226 a fitting into circumferential groove 216 of top panel 210 shown in FIG. 13B, edge 226 b fitting into the groove 225 of another wall panel 220 shown in FIG. 13C, and edge 226 c fitting into the circumferential groove 236 of base 230 shown in FIG. 13D, which may generally form substantially continuous interfaces between the components at top interface 202, side interfaces 204 and base interface 206, with minimal space and/or gaps between the components. The interfacing grooves, extensions and/or corner interfaces may also generally act as tongue and groove interfaces, and may thus provide rigid and/or largely self-supporting connections between the components which may require minimal if any reinforcement when assembled. The interfaces may also generally resist loads in all directions.

In other embodiments, the wall panels 220, as illustrated in FIGS. 13 and 13A, may also include an outer panel 222 joined and/or formed as a unitary component with an inner panel 226. The outer panel 222 may generally include an interface feature on one side, such as the corner interface 234, which may generally extend past the edge of the inner panel 226, as illustrated. In some embodiments, the corner interface 234 may generally include a substantially L-cross section such that it may substantially span a 90° corner for interfacing with another wall panel 220. The L-cross section of the corner interface 234 may generally form a groove 225 between the corner interface 234 and the inner panel 226.

The inner panel 226 may generally include interfaces which extend past the edges of the outer panel 222 except on the edge with the corner interface 234, such as with extensions 226 a, 226 b and 226 c, as illustrated. The extensions 226 a, 226 b and 226 c may generally be shaped to fit into grooves of other components of the container 200, such as, for example, the extension 226 a fitting into circumferential groove 216 of top panel 210 shown in FIG. 13B, extension 226 b fitting into the groove 225 of another wall panel 220 shown in FIG. 13C, and extension 226 c fitting into the circumferential groove 236 of base 230 shown in FIG. 13D, which may generally form substantially continuous interfaces between the components at top interface 202, side interfaces 204 and base interface 206, with minimal space and/or gaps between the components. The interfacing grooves, extensions and/or corner interfaces may also generally act as tongue and groove interfaces, and may thus provide rigid and/or largely self-supporting connections between the components which may require minimal if any reinforcement when assembled. The interfaces may also generally resist loads in all directions.

In some embodiments, the wall panels 220 may be identical and may form a container with a square cross-section. This may be desirable as the total number of different components required is three (top panels, bases and wall panels). In other embodiments, wall panels 220 of different dimensions may be used, for example, with two wall panels of one length and two wall panels of another length, such that the container cross-section will be a rectangle. In general, the dimensions of the top panel 210 and the base 230 may determine the required type of wall panel 220 to be used.

In general, the container 200 may be assembled by interfacing the wall panels 220 with the base 230 and capping with the top panel 210, as illustrated in FIG. 15. Since all of the corner interfaces 224 and the extensions 226 a, 226 b and 226 c project from a single plane, the wall panels 220 may be inserted into the base 230 one at a time, such as by a single assembler, and the wall panels 220 may interface with each other and the base 230 through purely vertical translation, as illustrated in FIG. 15, which may be desirable to reduce awkward and/or difficult assembly steps.

The base of a container may generally include a plurality of supports, such as legs, which may take various forms or shapes, such as illustrated with the legs of bases 900, 910 920 and 930 in FIGS. 16, 16A, 16B, 16C, 16D and 16E. The supports may generally space the bottom surface of the base from the ground and/or other surface. The supports may also be spaced from each other such that, for example, the base may be manipulated with a forklift and/or other moving machinery fitting into the spaces between the supports.

FIGS. 16 and 16A illustrate a plurality of legs 904 extending from the bottom surface 902 of the base 900. In some embodiments, the legs may have some angled walls and may have outer walls on the periphery of the base substantially perpendicular to the bottom surface 902, as illustrated with legs 904.

In some other embodiments, the legs may be have angled walls and be spaced inward from the outer periphery of the base, such as the legs 914, 924 and 934 of bases 910, 920 and 930, respectively, illustrated in FIGS. 16B, 16C, 16D and 16E.

Runners, bridges and/or other connectors may also be included, such as, for example, connecting multiple supports, which may generally increase the strength and/or rigidity of the base. FIG. 16A illustrates an example of crossed runners 906 connecting multiple legs 904. FIG. 16C illustrates an example of runners 926 connecting sets of three legs 924 along two edges. FIG. 16D illustrates an example of runners 916 connecting three sets of legs 914 in a parallel arrangement. In general, any desired combination of legs may be connected by runners or bridges. The runners or bridges may be manufactured from any suitable material. For example, the bridges may be constructed from wood, metal and/or various plastics materials, including those mentioned above for manufacturing the film covering such as lead free PVC. In some embodiments, the runners or bridges are manufactured from HIPS (high impact polystyrene) using an extrusion forming process. Further, the bridges may be configured so that they each span two or more supports of a row and may be affixed to the ends of said supports so that they interconnect. For example, the bridges may be affixed using a suitable adhesive.

As mentioned above, the runners or bridges may be attached to the bottom of the supports, either flushed with the bottom portions of the supports, for example, attached within an indented portion formed in the bottom of the supports, such as shown in FIGS. 16C and 16D, or protruded from the bottom portions of the supports, such as shown in FIG. 16A, and thus improves the wear and tear of the supports. In addition, the bottom of the runners or bridges may also be roughened to improve slip resistance of the base.

The bottom surface of the base and/or the sides of the supports may also include ridges, ribs, reinforcements and/or other surface modifications, as shown in FIGS. 16B, C and D, to which may, for example, aid in increasing the strength and/or rigidity of the structure of the base, especially under load. It is also believed that the ability of the supports and/or base to resist compressive loads is greatly enhanced if each of the side walls includes a plurality of generally longitudinally extending ribs. FIGS. 16B and 16D illustrate an example of ridges or ribs 913 interconnecting on the walls of the legs 914 and the bottom surface 912. FIG. 16C illustrates an example of grooves 923 on the bottom surface 922, with unconnected ridges or ribs on the legs 924. FIG. 16E illustrates an example of larger raised ribs 933 on the bottom surface 932 from which the legs 934 extend. The cargo containers may also include a desiccant to control the humidity of the interior.

In another exemplary embodiment of the invention, the container 200 is formed from two halves, and each of the halves may or may not include the top or the bottom components. The interfacing locking features on the components may include any or all combinations of those described above. In one embodiment, the container 200 includes two identical or mirror images substantially L-shaped cross-sectional halves, such as the halves 220′ illustrated in FIGS. 17 and 17A, each having at least two wall components 220, each of the components having corresponding interlocking features to be mated together to form a container having for example, a closed enclosure therein when mated with the top 210 and bottom 230 components, as shown in FIG. 17B.

In another embodiment of the invention, the container 200 includes two identical or mirror images of substantially L-shaped cross-sectional halves, such as the halves 210′ and 230′ as illustrated in FIGS. 18 and 18A, each having at least two walls 220 and a top component 210 or a base 230, respectively, joined to halves, each of the components having corresponding interlocking features to be mated together to form a container having for example, a closed enclosure therein.

For a container formed from two identical, substantially L-shaped cross-sectional halves 220′, or walls, each half 220′ may be integrally formed or joined from two of the wall sections 220, as discussed above, to interface with a top 210 and a base 230 component. The wall sections may generally be identical or similar in shape and size, and though integrally formed or joined together, each still kept its distinct platform portion 228. The halves 220′ may further include all of the features of the constituent wall sections 220, as above, except where the halves 220′ are integrally formed, the features that would normally interface the two constituent wall sections 220 may be absent and may instead form a solid continuous structure. In these embodiments, each half 220′ includes two vertical edges, such as interfaces 224 and 226 b, and two horizontal edges, such as 226 a and 226 c, to interconnect with other components, for example, with each other and with the top 210 and base 230 to form the container 200 with internal space 201, as illustrated in FIG. 17B. The halves 220′ may, such as by virtue of their shape and by being identical, may nest together which may generally conserve space during storage in knocked down form.

In one embodiment, one substantially L-shaped cross-sectional half may be integrally formed or joined with a top component, as shown with half 210′ formed from wall sections 220 joined to the top 210 as illustrated in FIG. 18A, while another substantially L-shaped cross-sectional half may be integrally formed or joined with a bottom or base component, as illustrated in FIG. 18 with half 230′ formed from wall sections 220 joined to the base 230, such that the two halves 210′, 230′ may be assembled to form a complete enclosed container 200, as illustrated in FIG. 18B. As with the halves 220′, the wall sections in the halves 210′, 230′ may generally be identical or similar in shape and size, and though integrally formed or joined together, each still kept its distinct platform portion 228. The halves 210′, 230′ may further include all of the features of the constituent wall sections 220, as above, except where the halves 210′, 230′ are integrally formed, the features that would normally interface the two constituent wall sections 220 and the top 210 or base 230 may be absent and may instead form a solid continuous structure. In these embodiments, each half 210′, 230′ includes two vertical edges, such as interfaces 224 and 226 b, and two horizontal edges, such as 226 a and 226 c, to interconnect with other components, for example, with each other, and the base 230 may include a groove 236 to interface with the edges of the half 210′ while the top 210 may include a groove 216 to interface with the edges of the half 230′ to form the container 200 with internal space 201, as illustrated in FIG. 18B. The halves 210′, 230′ may, such as by virtue of their shape and by being similar, may nest together with other halves of the same type or the other type, which may generally conserve space during storage in knocked down form.

For the halves 210′, 220′, 230′ as described above, the edges may be rounded or chamfered, as illustrated with, for example, the rounded edges 223, or they may also be substantially 90 degree interfaces which are not rounded or smoothed (not shown).

As noted above, the interfacing features may be formed during any step of the manufacturing process. In one example, the features may be molded when the components are made. The base, top or walls may include a light weight core, for example, a closed cell foamed core, combined with or surrounded by a polymeric film to form a strengthened structure. The core may include the interfacing features and the polymeric film may then conform to the features in the core during the combining or surrounding step or process. In another embodiment, the features may be forged into the components after the components are made. For example, the base, top or walls may include a light weight core, for example, a closed cell foamed core, combined with or surrounded by a polymeric film to form a strengthened structure. The core does not include any of the interfacing features. The interfacing features may then be forged after the core and film are combined, and the exposed surface of the core may either remain exposed or a spray coating made be added to cover the exposed surface of the core. In a further embodiment, for example, liquid polyurethane may be injected into a mold to form a polyurethane core containing grooves, channels, protrusions, ridges, extensions, wrapping portions and/or pockets which after curing is removed from the mold and sprayed with polyurea to form one or more of the load bearing structures having interfacing features. Using this molding process, size and shape may be easily varied. In yet another embodiment, any light weight core may be covered with a spray coating after forging all the features, for example, any closed cell foam may be sprayed coated with a polyurea coating after interface features are forged.

In various embodiments of the invention, one or more of the dunnage platform, the first enclosure and second enclosure are formed from a core, from one or more of the materials including expanded polystyrene, polyurethane, polyphenylene ether, polystyrene impregnated with pentane, a blend of polyphenylene ether and polystyrene impregnated with pentane, polyethylene, and polypropylene. In various embodiments of the invention, one or more of the dunnage platform, the first enclosure and second enclosure are formed from a core containing one or more materials mentioned above. In various embodiments of the invention, one or more of the dunnage platform, the first enclosure and second enclosure are formed from one or more thermoplastic sheets or layers including high impact polystyrene, polypropylene, polycarbonate, low density polyethylene, high density polyethylene, polypropylene, acrylonitrile butadiene styrene, polyethylene, polyacrylonitrile, polyurea, polybutadiene, polyphenylene ether and polyphony ether alloyed with high impact polystyrene. In various embodiments of the invention, one or more of the dunnage platform, the first enclosure and second enclosure thermoplastic sheets are a blend of any of the polymers mentioned above. In various embodiments of the invention, one or more of the dunnage platform, the first enclosure and second enclosure are formed from a core with an embedded strengthening material selected from the group consisting of a mesh, a perforated sheet and a barrier is embedded in the core. In various embodiments of the invention, one or more of the dunnage platform, the first enclosure and second enclosure are formed from a core with an embedded strengthening material selected from the group consisting of metal, carbon fiber, Kevlar, basalt-web blanket and Formica. As noted above, when used in facilitating security check of air cargo transport of cargo that is transparent to magnetic scanners, non-metal containers may be used.

In embodiments of the invention, one or more of the load bearing structure and the half enclosures may be made of an expanded polymer core over which one or more thermoplastic sheet are combined. The expanded core may be made from already manufactured bulk form, such as expanded polystyrene foam which may be cut to the desired shape and size; or may be foamed in place in a mold of the size and shape desired, such as polyurethane foam. The foam density may also be varied, depending on the degree of expansion of the beads used to make the foam. The foam density may also decide the suitable load or cargo to be loaded. In general, the bead density for the foam may vary between 25-30 Kg/m³ if it is polystyrene. It is surmised that, for a given foam material, the higher density of the resulting foams, the higher strength of the resulting load bearing structures. However, higher density foams also increases the weight of the resultant load bearing structure. Thus, it is desirable to tailor the correct density of the foam for the utility at hand.

For lower density beads, the resultant foam may or may not be structurally weaker with the same degree of bead expansion. Thus, material of the foam may also be considered for the tailoring.

No matter what the material of the expanded core is, it is in general by itself, unless it is of higher density, for example, the beads are not highly expanded, may not have sufficient structural strength to be useable as a load bearing platform. However, structural strength may be improved when the cores are combined with polymeric sheets regardless of the density of the foam or core.

In an embodiment of the invention, one or two high impact polystyrene sheets are combined with an expanded polystyrene core containing grooves, protrusions and/or pockets to form one or more of the load bearing structure and the half enclosures. In an alternative embodiment of the invention, one or more of the load bearing structure and the half enclosures may be made by injecting a polymer into a mold to form the core and after removing the core from the mold spraying a polymer coating on the polymer core. In an embodiment of the invention, liquid polyurethane is injected into a mold to form a polyurethane core containing grooves, protrusions and/or pockets which after curing is removed from the mold and sprayed with polyurea to form one or more of the load bearing structure and the half enclosures. For example, the polyurea spray coating process may form a coating of about 0.1 to about 0.5 mm thick on a about 50 mm core. In various embodiments of the invention, the mold may be made of metal, plastic or natural materials including wood. In an embodiment of the invention, the mold is made of aluminum.

In one embodiment, at least one antimicrobial agent may be added to the material used for making the polymeric layer, for example. The antimicrobial agent may be in powder form or in liquid form. In another embodiment, at least one antimicrobial agent may be coated onto the exposed surface of the polymeric layer, for example. The antimicrobial agent may be in powder form or in liquid form.

When the antimicrobial agent or agents are incorporated in the material used in making the polymeric layer, for example, a sheet or sprayed coating, the agent or agents maybe dispersed directly into the material, or with the aid of an appropriate carrier, for example, a binding agent, a solvent, or a suitable polymer mixing aid. These carriers may also be useful for coating aids mentioned above. Effective binding agents are those that do not interfere with the antimicrobial activities of the antimicrobial agent. In one embodiment, when the anti-microbial agent is incorporated into the material used either for making the polymeric layer, for example, a sheet or sprayed coating mentioned above, the antimicrobial agent maybe master batched in the material or an appropriate carrier at a higher concentration prior to adding to the material for making the polymeric layer, for example, a sheet or sprayed coating in desired proportions. In another embodiment, the antimicrobial agent may be added directly to the material for making the polymeric layer, for example, a sheet or sprayed coating without the intermediate step.

In other embodiments, the antimicrobial agents, either in coatings or incorporated into the materials for making the polymeric layer, for example, sheets or surface coatings, may include chemical antimicrobial materials or compounds that may be deposited in a non-permanent manner such that they may slowly dissolve, slowly leach or otherwise deliver antimicrobial substances during use. The antimicrobial material may be adequately incorporated, though temporarily and/or in sufficient amounts to last at least for a period such as the useful life of the load bearing structures, either when at least one antimicrobial agent is added to the material used for making the polymeric layer, for example, a sheet or sprayed coating mentioned above, or when at least one antimicrobial agent is coated onto the exposed surface of polymeric layer, for example, the sheet or sprayed coating mentioned above; or maintain their anti-microbial effects when at least one antimicrobial agent is coated with the aid of coating agents, onto the exposed surface of the polymeric layer, for example, a sheet or sprayed coating mentioned above. The suitable agent or agents are those that tend to slowly migrate, or are non-leaching as defined below, to the surfaces to provide antimicrobial properties to the surfaces.

In still other embodiments, the antimicrobial agent either in coatings or incorporated into the material used for making the polymeric layer, for example, sheets or sprayed coatings may include sources of anti-microbial agents which may leach and/or release agents in a moist environment or upon contact with moisture. These sources may be incorporated into the substrate materials used for manufacturing the polymeric layer, for example, sheet mentioned above, or included in the coatings spray coated on the exposed surfaces of the core or sheet. Incorporation of these sources may be especially suited to polymeric substrates.

Antimicrobial agents may be employed to retard or kill microbes on the exposed surface or surfaces of the container. Antimicrobial agents may include, but are not limited to, antibiotics such as β-lactams (e.g. penicillin), aminoglycosides (e.g. streptomycin) and tetracylcines (e.g. doxycycline), antimycotics such as polyene drugs (e.g. amphotericin B) and imidazole and triazole drugs (e.g. fluconazole), and general antimicrobial agents such as quaternary ammonium cations (e.g. benzalkonium chloride) and compounds such as triclosan, chlorhexidine, a source of metal ions and/or any other appropriate compound or mixtures thereof.

In some embodiments, the agent or agents may include chemical anti-microbial materials or compounds that are capable of being substantially permanently bonded, at least for a period such as the useful life of the container 500, 600 or 800, or maintain their anti-microbial effects when coated with the aid of coating agents, onto the exposed surfaces of the container 380, 600 or 800. In one example, the chemicals may be deposited on the exposed surface or surfaces of the container 380, 600 or 800 by covalent linkage or linkages.

The substantially permanent anti-microbial coating may be, for example, substantially flexible so that the coating substantially covers the working surfaces of the load bearing structure during use even if the structure flexes. If the anti-microbial compound is not capable of forming a substantially flexible coating by itself, then a binding agent capable of forming a substantially flexible coating may be used to aid in the flexibility of the resulting coating.

In one embodiment, a porous sheet substrate or surface of the core 115, for example, an expanded polystyrene core or polyurethane core, may be impregnated with a water based antimicrobial composition, having at least one polymeric carrier that may be in the form of an emulsion or dispersion and at least one substantially non-leaching antimicrobial component that is substantially free of environmentally hazardous material. The porous substrate may or may not additionally be overcoated or protected with a film layer.

In another embodiment, a porous sheet substrate or surface of the core 115, for example, an expanded polystyrene core or polyurethane core, may be impregnated with a water based antimicrobial composition, having at least one polymeric carrier that may be in the form of an emulsion or dispersion and at least one surface active antimicrobial component that is substantially free of environmentally hazardous material.

In yet another embodiment, a non-porous sheet substrate 115 may be coated with a water based antimicrobial composition, having at least one polymeric carrier that may be in the form of an emulsion or dispersion and at least one substantially non-leaching antimicrobial component that is substantially free of environmentally hazardous material.

For load bearing structures having one thermoplastic sheet 115 over the core thereon, the exposed surfaces may be porous, as noted above. The porous material may be impregnated with a water based antimicrobial composition, also as mentioned above, making the surface non-porous.

In some embodiments, the surfaces of the porous materials impregnated with an antimicrobial composition may be non-porous after drying or setting and may perform as if it has been coated or covered with a thermoplastic sheet or layer mentioned above.

The same emulsion or dispersion mentioned above may also be coated onto the exposed surfaces of load bearing structures having two thermoplastic sheets over the core thereon.

Examples of antimicrobial component that is substantially free of environmentally hazardous material may include sodium omadine, sodium borate, zinc omadine, zinc borate, calcium borate, barium metaborate, iodo alkynyl alkyl carbamates, diiodomethyl-p-tolylsulfone, 2-4-thiazolyl-benzimidaxole, 2-n-octyl-4-isothiazolin-3-one, zinc dimethyldithiocarbamate, zinc 2-mercaptobenzothiazole, potassium n-hydroxymethyl-n-methyldithiscarbamate, sodium 2-mercaptobenzothiazole, 5-hydroxyemthoxymethyl-1-aza-3,7-dioxa-bicyclooctane, 2,3,5,6-tetra-chloro-4-pyridine, zinc 2-pyridinethiol-1-oxide and N-trichloromethylthiophthalimide, tetrachloroisophthalonitrile, deltamethrin, fipronil, bifenthrin, chlorfenapyr, imidacloprid, and mixtures thereof. For use in facilitating security check, metallic compounds are not used.

Non-leaching antimicrobial materials are, for example, materials with a very low volatility and very low water solubility such that it would only leach out to the extent sufficient to maintain an effective and uniform concentration throughout the exposed surface(s) of the antimicrobial article when its concentration thereon may be reduced due to its action against microorganisms. In other words, the antimicrobial component may be selected not to be fugitive or migrating once being incorporated into the impregnated article, but to have a very low water solubility so that it may maintain an equilibrium concentration throughout the article on its surface(s) whenever the concentration reduction occurs due to the attack of the microbes. The antimicrobial component may have a water solubility of, for example, from about 0.10 PPM to about 1.0 wt %, depending on each individual antimicrobial component.

For example, the polymeric emulsion or dispersion may have a medium particle size of from about 0.10 micron to about 4.0 micron. Examples of useful polymeric emulsion or dispersion includes, such as, emulsions or dispersions of styrene acrylic copolymers, such as Acronal 5702 from BASF, Ucar 376 from Union Carbide, and Res 3077 from Rohm & Haas; styrene butadiene block copolymers, such as, DL 313 NA from Dow Chemical, ND-565 and ND-422 from BASF, and Rovene 6105 from Mallard Creek Polymers; ethylene vinyl acetate copolymers, such as Airflex 400/A405/460 from Air Products and Elvace 1875 from Reichhold Chemicals; polyvinyl acetate homopolymer, such as PD-316 from H.B. Fuller Company, and Airflex XX-220/230 from Air Products; acrylate-acrylonitrile copolymers, such as Synthemuls, various grades from Reichhold Chemicals; vinyl acetate-vinyl chloride ethylene copolymers, such as Airflex 728 from Air Products; ethylene vinyl acetate butyl acrylate terpolymers, such as Airflex 809 from Air Products; butadiene-acrylonitrile copolymers, such as Tylac, various grades from Reichhold Chemical; vinyl acrylic-vinyl chloride, such as Haloflex 563 from Zeneca Resins; vinylidene chloride-acrylic-vinyl chloride copolymers, such as Vycar 660X14 and Vycar 460X46 from B.F. Goodrich; chloroprene polymers and copolymers, such as DuPont Neoprene latex 115, 400, 654 and 750 from DuPont; water-borne urethane polymers, such as Neo Rez R-962, 967 and 972 from Zeneca Resins, and mixtures thereof.

In various embodiments of the invention, a lightweight mesh is embedded in the polymer core prior to application of the thermoplastic sheet to one or more surfaces of the polymer core. The mesh may be polymeric or metal, except when containers are to be used in facilitating security check of air cargo transport of cargo that is transparent to magnetic scanners, polymeric mesh may be used.

In an embodiment, a thin perforated sheet or barrier is spaced away from a thermoplastic sheet which forms a part of a mold and the polymer core fills the vacancy between the thermoplastic sheet and the mold surrounding the thin perforated sheet. In an alternative embodiment, a thin perforated sheet or barrier is positioned inside a mold and the polymer core fills the mold surrounding the thin perforated sheet. In an embodiment of the invention, a lightweight mesh is embedded between the expanded polystyrene core and the high impact polystyrene sheet. In an embodiment of the invention, a lightweight mesh is embedded between the polyurethane core and the polyurea coating applied over the lightweight mesh. In one embodiment the mesh, perforated sheet or barrier is metallic. In another embodiment the mesh, perforated sheet or barrier is made of Kevlar. In a different embodiment the mesh, perforated sheet or barrier is made of a basalt web blanket material. In a further embodiment the mesh, perforated sheet or barrier is made of carbon fiber. In another embodiment the mesh, perforated sheet or barrier is made of Formica.

After loading the cargo container, the interior may be further sealed from the exterior by wrapping cellulose film, polyvinyl chloride film, polyvinylidene chloride film, low density polyethylene film, linear low density polyethylene film and copolymer films that include polyisobutene and/or polyethylene-vinylacetate.

In other embodiments, the cargo container may be covered by a flexible and strong, bag-like material 70 to contain and protect the cargo from being removed and/or misplaced, as shown in FIGS. 10 and 10A. For example, the material may be a film, a woven sheet or a non-woven sheet having sufficient strength for stretching over and covering a cargo and light weight enough not to add unnecessary weight to the cargo.

The bag-like material 70 may be closed on three sides and opened at one end, with the open end having some elastic property circumferentially about the opening. The cargo may be packed and the bag-like material 70 stretched over the entire cargo with the open end stretched under the edge of base and tagged at the origin and the complete structure may be shrink-wrapped. The surfaces of the bag-like material may also have anti-microbial properties.

By imbedding mesh, a perforated sheet or a barrier within the core, the cargo container base, walls and top panel may not be simply punctured or pierced with items such as knives, chisels, crowbars or other such devices (i.e., puncture resistant). As such the cargo container is defined as being ‘tamper-resistant’ meaning that the integrity of the container is not susceptible to attack by persons wielding instruments that may be concealed under items of clothing. Tamper resistant is a less stringent requirement than safe. Tamper resistant is designed to insure that the container may not be broken into by an opportunistic thief. That is persons having instruments that may be concealed under items of clothing and used to break or disturb the integrity of the container. Tamper resistant does not secure a container against heavy equipment, or power tools.

In an embodiment of the invention, the mesh, perforated sheet or barrier is made of a conducting material and is connected to a voltage supply such that contact with the surface of the mesh, perforated sheet or barrier will transmit an electric shock. The electric shock may be controlled by a microprocessor to deliver one or more combinations of low voltage low current or high voltage low current shocks. The microprocessor may be inserted in the core or positioned inside the cargo container and connected to the mesh, perforated sheet or barrier. The voltage supply may be inserted in the core or positioned inside the cargo container and connected to the microprocessor circuit and the mesh, perforated sheet or barrier inside the cargo container. In an alternative embodiment of the invention, a warning siren, flashing light or foul odor alarm may be activated by the microprocessor when the integrity of the cargo container is breached. The warning siren alarm may be positioned in the core or inside the cargo container and connected to the microprocessor circuit and the voltage supply. The foul odor alarm may be positioned in the core or inside the cargo container with a cavity connecting the odor reservoir to the outside of the container and a relay valve connected to the microprocessor circuit. The flashing light alarm may be inserted in the core where the light may penetrate through the thermoplastic sheet and may be connected to the microprocessor circuit and the voltage supply. In this embodiment, the mesh, perforated sheet or barrier may be light weight and electrically conducting. When the integrity of the mesh, perforated sheet or barrier is disrupted a voltage meter senses the reduced voltage being conducted and sets off the alarm. A light emitting diode or other warning may be visible on the exterior of the cargo container and may be used to alert handlers that the cargo container is wired to an alarm system. A sensor may relay a signal to the microprocessor and may be used by the client or the shipping agent to disconnect the voltage supply or otherwise disarm the alarm, prior to unloading the cargo container on arrival at the destination.

In another embodiment of the invention, the cargo container base is made of a polymer core in which either mesh, a perforated sheet or a barrier are imbedded. The core may be combined with a thermoplastic sheet or the core may be injected into a mold in which the thermoplastic sheet forms a portion of the mold. The cargo container walls and top panel may also be made of a core in which either mesh, a perforated sheet or a barrier are imbedded. In various embodiments, the reinforced materials are indistinguishable from the non-reinforced materials when subjected to visual inspection. In this way an opportunistic thief may not be certain how difficult it may be to gain entry to any given cargo container. In various embodiments of the invention, the cargo container exterior surfaces may be imprinted with information warning that approximately safety and or theft protection measures are required when handling the cargo container.

Phase change materials may include organic materials, inorganic materials, their acids and their salts. Organic materials have their own advantages and disadvantages. Of the organic PCMs, most may be exposed to air, have wider ranges of melting temperatures. However, organic PCMs may be flammable, combustible and may have lower specific heat. Inorganic materials also have their own advantages and disadvantages. Inorganic salts often may have to be enclosed or encapsulated to prevent or minimize water evaporation or uptake. Inorganic PCMs generally have higher specific heats than organic PCMs. Combining organic PCMs and inorganic PCMs may have advantages for certain applications. If the phase change materials are correctly utilized, some of the disadvantages may become an advantage for certain applications.

Both organic PCMs and inorganic PCMs may be used in their pure form, combined or may be formulated with other substances to expand the usefulness over extreme temperature ranges.

Common organic PCMs include paraffin waxes, 2,2-dimethyl-n-docosane (C₂₄H₅₀), trimyristin, ((C₁₃H₂₇COO)₃C₃H₃), 1,3-methyl pentacosane (C₂₆H₅₄), other polyethylene waxes, ethylene-bis-stearamide, N,N-ethylene-bis-stearamide, which may be used alone or in mixtures thereof. Common inorganic PCMs include anhydrous sodium acetate, sodium acetate solutions, hydrated salts including sodium hydrogen phosphate dodecahydrate (Na₂HPO₄.12H₂O), sodium sulfate decahydrate (Na₂SO₄.10H₂O), ferric chloride hexahydrate (FeCl₃.6H₂O), TH29 (a hydrated salt having a melting temperature of 29° C., available from TEAP Energy of Wangara, Australia), Sodium Sulfate Decahydrate, which may be used alone or in mixtures thereof. Other inorganic PCMs include metallic alloys, such as Ostalloy 117 or UM47 (available from Umicore Electro-Optic Materials).

The most commonly used PCMs are salt hydrates, fatty acids and esters, various paraffins (such as octadecane), though ionic liquids may be possible.

Eutectic or near eutectic mixtures may be formed. Examples include salt solutions, ethylene diamine mixed with a noncorrosive material or materials such as dimethyl sulfoxide and/or dimethyl sulfone and/or H20, and/or paraffin mixed with detergent (to permit the paraffin to dissolve in the ethylene diamine), and/or phenyl salicylate, and ethylene diamine solutions in dimethyl sulfone (DMSO). Some of these mixtures may have melting temperatures below approximately 5° C. to approximately −23° C. More details may be found in U.S. Pat. No. 4,719,028, the contents of which are hereby expressly incorporated by reference in its entirety.

In an embodiment of the invention, PCMs suitable for keeping contents cool may be solids at ambient temperature, having melting points between approximately 30° C. and approximately 50° C. Further, eutectic or near eutectic mixtures may be formed.

In an embodiment of the invention, PCMs suitable for keeping contents cool may be solids at ambient temperature, having melting points between approximately 35° C. and approximately 45° C. Other examples, such as those solids with a low melting point, for example, freeze salts may be suitable for keeping contents from being subjected to temperatures that are too cold for the content and/or from freezing.

In general, a higher specific heat may be advantageous, and may, for example, have a specific heat of at least approximately 1.5. In an embodiment of the invention, PCMs for keeping contents cool may have a high specific heat, for example, at least approximately 1.7. In an embodiment of the invention, PCMs, when they are in the state at ambient temperature, may have a specific heat of at least approximately 1.9. In an embodiment of the invention, PCMs, when they are in the state at the elevated temperatures may have a specific heat of at least approximately 1.6. In an embodiment of the invention, PCMs with a high specific heat may be advantageous for keeping the contents from being too cold and/or from freezing.

In general, small volume changes on phase transformation and small vapor pressure changes at operating temperatures to reduce the containment problem may also be advantageous.

Phase change materials present many suitable options for customized climate control. For each application, a material, a mixture of materials or a formulated material having the desired melting temperature range in the desired operating temperature range may be chosen along with other desirable properties.

In addition to containment of phase change materials as previously discussed, encapsulation of PCMs may also be possible, not only for containment, but for increased flexibility and property improvement. For example, micro-encapsulation may allow PCMs to be incorporated into construction materials. Micro-encapsulated PCMs includes coating a microscopic sized PCM with a protective coating. In this form, inorganic PCMs may be transformed into material that may be exposed to air or water, or be transformed from being hygroscopic to non-hygroscopic. Molecular-encapsulation is another technology, developed by Dupont de Nemours that may enclose a very high concentration of PCM within a polymer compound. Molecular-encapsulation allows drilling and cutting through the material without any PCM leakage.

As noted above, combinations of phase change materials (PCMs) and other (usually solid) structures are generally possible. In an embodiment of the invention, metallic alloys, may be better thermal conductors than other phase change materials even though their heat of fusion are low. Thus a mixture of a metallic alloy with one or more of the other inorganic or organic phase change materials may be used to increase heat conductivity within the phase change material. A simple example is a copper-mesh immersed in a paraffin-wax. The copper-mesh within paraffin-wax may be considered a composite material. Such a composite also adds increased thermal conductivity to the PCMs. Such composites may include using fiber-glass or kevlar-pre-preg and a matrix. The matrix may be any adhesive which may solidify to hold fibers together and provide compressive strength. In an embodiment of the present invention, the PCM material, either in pure form, in mixtures, or in encapsulated form may be held in the cargo container. In an embodiment of the present invention, the PCM material may be included in compartments in the foam used for the construction of the container. In an embodiment of the present invention, the PCM material may be added to the foam used for the construction of the container.

In an embodiment of the invention, PCMs are combined with hygroscopic substances to control the humidity in the container. Examples of hygroscopic materials include calcium chloride, zinc chloride, potassium hydroxide, sodium hydroxide, sodium chloride, sodium iodide, and anhydrous copper sulfate.

PCMs and hygroscopic substances may be enclosed in flexible plastic enclosures. In various embodiments of the invention, the flexible plastic enclosures are made of one or more materials selected from the group consisting of cellulose film, polyvinyl chloride film, polyvinylidene chloride film, low density polyethylene film, linear low density polyethylene film and copolymer films that include polyisobutene and/or polyethylene-vinylacetate.

As noted above, the storage or shipping containers may be square shape or may be of polygonal or clam shell shape. In one exemplary embodiment, a cargo container for insulating and transporting and/or storage of cargo may include a first structure having a load bearing portion and at least a first wall, at least one of the load bearing structure and at least one wall may include at least a first core and a first thermoplastic layer surrounding the first core; and a second structure having a top portion and at least a second wall, at least one of said top and at least one wall may include at least a second core and at least a second thermoplastic layer surrounding the second core; such that at least one of the load bearing portion, first and second wall and top portion includes at least one phase change material to insulate the cargo for climate control. The phase change material may be compounded into a composite, mixed or encapsulated. The encapsulated material may be particularly suited for dispersing with any of the core.

In another embodiment of the invention, a Radio Frequency IDentification (RFID) tag is imbedded in the core of one or more of the dunnage platform, the first enclosure and second enclosure. In one embodiment of the invention, the RFID tag operates using an Ultra High Frequency (UHF) signal. In another embodiment of the invention, the RFID tag operates using a microwave frequency signal.

In one embodiment, the RFID tag is centered in the middle of the core. In another embodiment, the RFID tag is placed on the edge of the core. In an embodiment of the invention, the RFID tag may be positioned so that the RFID tag antenna is least affected by the metal in the loaded cargo carrier.

In one embodiment of the invention, means of communication with a base station is imbedded in one or more of the dunnage platform, the first enclosure and the second enclosure. In one embodiment of the invention, the communication means utilizes one or more of a wireless local area network; a wireless wide area network; a cellular network; a satellite network; a Wi-Fi network; and a pager network. In one embodiment of the invention, the device embedded is a modem capable of communicating with one or more of the aforementioned networks. In the following discussion the term ‘cellular modem’ will be used to describe the device embedded. The term ‘cellular modem’ will be herein used to identify any device of comparable size capable of communicating over one or more of the aforementioned networks. In one embodiment of the invention, the cellular modem may be a Code Division Multiple Access (CDMA) modem. In an embodiment of the invention, a RFID reader and associate integrated circuit processor are embedded together with the cellular modem in the spreader, the transporter base, the dispenser base, the reloading base and the material of the four walls. In such an embodiment, the RFID tags and RFID reader are positioned to optimize the RFID read of the RFID tags from the other surfaces.

In an embodiment of the invention, where a RFID reader and a cellular modem are embedded; the RFID reader is in communication with one or more RFID readers, associated cellular modems and the RFID tags of one or more cargo carriers in the vicinity of the RFID reader. Through communications with the RFID reader and associated integrated circuit processor of the plurality of cargo carriers in the vicinity, a RFID reader and associated integrated circuit processor is able to distinguish the RFID tag from cargo loaded in cargo carriers in the vicinity based on one or more of location, strength of signal, variation of RFID tag signal with position in the cargo carrier relative to the reader, variation of RFID tag signal with time and prior input data. In an embodiment of the invention, one or more antennae inserted into the cargo carrier are used to help discriminate the location of the cargo carriers. In an embodiment of the invention, the RFID reader and associate processor are in communication with the embedded cellular modem. In an embodiment of the invention, the cellular modem is in communication with a base station and may transmit one or more parameters selected from the group consisting of one or more RFID tag location, one or more RFID tag identification code, number of cargo carriers, cargo carrier information, previous cargo information, dunnage platform condition, enclosure condition, cargo carrier condition and time stamp.

In another embodiment of the invention, a RFID tag is embedded in one or more of a dunnage platform and a master dunnage platform.

In an embodiment of the invention, the cargo, each dunnage platform and a master dunnage platform contain one or more of a passive RFID tag, an active RFID tag and RFID tag reader. Each dunnage platform is able to monitor the cargo and the dunnage platforms in the vicinity. In a shipment, one or more master dunnage platforms contain an RFID tag reader which is able to monitor all the other dunnage platforms and cargo carriers in the vicinity of the one or more master dunnage platform. The master dunnage platform is then able to relay the position and condition of the entire shipment to a base station.

In one embodiment of the invention, means of communication with a base station is imbedded in a master dunnage platform. In an alternative embodiment of the invention, one or more dunnage platforms contain the apparatus to communicate with the base station in order to relay the condition and global position of the cargo. In an embodiment of the invention, two or more master dunnage platforms are used to communicate with a base station by transmitting or receiving simultaneously and signaling averaging or alternatively using the master dunnage platform which is best able to receive or transmit given their individual locations.

In one embodiment of the invention, the communication means utilizes one or more of a wireless local area network; a wireless wide area network; a cellular network; a satellite network; a Wi-Fi network; and a pager network. In one embodiment of the invention, the device embedded is a modem capable of communicating with one or more of the aforementioned networks.

In an embodiment of the invention, through communications with the RFID reader and associated integrated circuit processor of the one or more master dunnage platforms, a RFID reader and associated integrated circuit processor is able to distinguish the RFID tag from dunnage platforms in the vicinity of the one or more master dunnage platform based on one or more of location to each of the master dunnage platforms, strength of signal to each of the master dunnage platforms, variation of RFID tag signal with position relative to each of the master dunnage platforms, variation of RFID tag signal with time relative to each of the master dunnage platforms and prior input data. In an embodiment of the invention, one or more antenna can be used to help discriminate the location of the dunnage platforms position relative to the one or more master dunnage platforms. In an embodiment of the invention, the RFID reader and associate processor can be in communication with the embedded cellular modem. In an embodiment of the invention, the cellular modem is in communication with a base station and can transmit one or more parameters selected from the group consisting of one or more RFID tag locations, one or more RFID tag identification codes, previous shipment information, master dunnage platform information, dunnage platform condition and time stamp.

In one embodiment of the invention the RFID code uses the IEEE format and is Electronic Product Code (EPC) readable. In another embodiment of the invention the RFID code uses the UCC format and is Universal Product Code (UPC) readable. In another embodiment, the format is compatible for EPC, European Article Number (EAN) and UPC read and write functions.

Various embodiments can be implemented using a conventional general purpose or specialized digital computer(s) and/or processor(s) programmed according to the teachings of the present disclosure, as will be apparent to those skilled in the computer art. Appropriate software coding can readily be prepared by skilled programmers based on the teachings of the present disclosure, as will be apparent to those skilled in the software art. The invention can also be implemented by the preparation of integrated circuits and/or by interconnecting an appropriate network of component circuits, as will be readily apparent to those skilled in the art.

Various embodiments include a computer program product which is a storage medium (media) having instructions and/or information stored thereon/in which can be used to program a general purpose or specialized computing processor(s)/device(s) to perform any of the features presented herein. The storage medium can include, but is not limited to, one or more of the following: any type of physical media including floppy disks, optical discs, DVDs, CD-ROMs, micro drives, magneto-optical disks, holographic storage devices, ROMs, RAMs, EPROMs, EEPROMs, DRAMs, PRAMs, VRAMs, flash memory devices, magnetic or optical cards, nano-systems (including molecular memory ICs); paper or paper-based media; and any type of media or device suitable for storing instructions and/or information. Various embodiments include a computer program product that can be transmitted in whole or in parts and over one or more public and/or private networks wherein the transmission includes instructions and/or information, which can be used by one or more processors to perform any of the features, presented herein. In various embodiments, the transmission can include a plurality of separate transmissions.

Stored on one or more of the computer readable medium (media), the present disclosure includes software for controlling both the hardware of general purpose/specialized computer(s) and/or processor(s), and for enabling the computer(s) and/or processor(s) to interact with a human user or other mechanism utilizing the results of the present invention. Such software can include, but is not limited to, device drivers, operating systems, execution environments/containers, user interfaces and applications.

The execution of code can be direct or indirect. The code can include compiled, interpreted and other types of languages. Unless otherwise limited by claim language, the execution and/or transmission of code and/or code segments for a function can include invocations or calls to other software or devices, local or remote, to do the function. The invocations or calls can include invocations or calls to library modules, device drivers and remote software to do the function. The invocations or calls can include invocations or calls in distributed and client/server systems.

For cold chain cargo and its container, any tracking system may also help to monitor the cargo's integrity after packing and prior to security check.

The container thus formed may be able to withstand cargo weights up to many times the weight of the container, for example up to about 10 times, more for example, up to about 20 times, and even more for example, up to about 25 times the weight of the container itself, as noted above. A test was carried out to demonstrate this using one of the embodiments described above.

The exemplary containers used had components having the configuration and locking features similar to that shown in FIGS. 12, 12A, 13, 13A, 14, and 14A and assembled as depicted in FIG. 15. Each of the components was made from a polystyrene foam core having a density of about 1.5 lbs per cubic foot and covered by a layer of high impact polystyrene in one embodiment and polyurea in another embodiment. After the wall components 220, such as those shown in FIGS. 13 and 13A, were assembled on top of the bottom panel 230, such as depicted in FIGS. 12 and 12A to form an enclosure, a plastic bag (not shown) was deposited inside the enclosure and held open by the top panel 210 placed on top of the wall panels, such as depicted in FIGS. 13 and 13A. The assembled container had a capacity of holding 210 gallons of water, weighing about 1375 lbs. A water hose was inserted and water was delivered into the plastic bag until the container was about 90% full of water. The pressure from the water pressed against the wall panels 220 and the bottom panel 230, as evidenced by the slight bulging of the wall panels 220, but the interfacing features held the container together. It was estimated that about 190 gallons of water was inside the container. The water was left in the container for more than two hours, before checking for breakage or leakage. None was found. The container was then left standing for an additional 2 hours (a total of about 4 hours) before checking for breakage or leakage. Again, none was found.

Though the container was a light weight container, weighing about 50 lbs., the interface features were able to withstand about 25 times the weight of the container of water inside.

It will be appreciated by those of ordinary skill in the art that the present invention may be embodied in other specific forms without departing from the spirit or essential character hereof. The present description is therefore considered in all respects to be illustrative and not restrictive. The scope of the present invention is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein. 

What is claimed is:
 1. A container comprising: an assembly of a base, a top and at least two wall structures, each of said wall structures having an inside surface, an outside surface, a thickness joining the inside and outside surfaces, and four inside edges and four outside edges, a first of said outside edges of said wall structure having an interface feature comprising an extension, said extension having a thickness and a wrapping portion that wraps at a substantially 90° angle about a portion of said corresponding first inside edge, forming a channel therebetween the inside and outside surface.
 2. The container of claim 1 wherein a second of said inside edges having an interface feature that extends beyond said second outside edge, said interface feature having a thickness for mating with said channel formed by said wrapping portion of an adjacent wall.
 3. The container of claim 1 wherein said wrapping portion has a rounded outside surface.
 4. The container of claim 2 wherein said wrapping portion comprises a shape such that mating of adjacent walls generates a rounded, chamfered and/or otherwise shaped corner of the container.
 5. The container of claim 1 wherein said base having a top surface, a bottom surface with a thickness joining the top and bottom surfaces, said top surface comprises a platform portion, a circumferential edge portion, and an interface feature disposed between said platform portion and said circumferential edge portion, said interface feature comprises a groove, a channel, a protrusion, a ridge, a step edge configuration or combinations thereof.
 6. The container of claim 1, wherein said base, top and wall structures interfaced together with features comprising respective depression, channels, ridges, protrusion and extensions having wrapping portions matting to form an enclosure without any aid from any component that is not part of the base, top or wall structures that form the container.
 7. The container of claim 6, further comprising slots formed or molded onto the inside surface of at least three of the base, and wall structures for locating at least one divider to form multiple compartments inside the enclosure.
 8. The container of claim 1, wherein each of said at least two wall structures comprises two wall components integrally formed together to form a substantially L-shape half.
 9. The container of claim 1, further comprising a pocket on the inside surface of any of the wall structures and top surface of the base for containing a phase change material.
 10. A container for loading and transporting a cargo item comprising: a base structure having a top surface and a bottom surface joined by a thickness, said top surface having a main platform portion, an interface feature surrounding the main platform portion, and an outer edge portion surrounding the interface feature; and two identical wall structures, each of said wall structures having an inside surface, an outside surface, a thickness joining the inside and outside surfaces, four inside edges and four outside edges; wherein each wall structure having an interface feature for mating with said interface feature of said base and an interface feature for mating with an interface feature of an adjacent wall to form an enclosure; wherein a first of said outside edges of each of said wall structures having an interface feature comprising an extension, said extension having a thickness and a wrapping portion that wraps at a substantially 90° angle about a portion of said corresponding inside edges, forming a channel therebetween the inside and outside surface for receiving a corresponding mating interface feature of one of other said edges of an adjacent wall structure.
 11. The container of claim 10, wherein said interface feature of one of the other edges of said adjacent wall structure comprises a protrusion or ridge.
 12. The container of claim 10, wherein any of the surfaces has antimicrobial properties.
 13. The container of claim 10 wherein said interface feature of said base comprises a protrusion, a ridge, a channel, or a groove.
 13. The container of claim 10, wherein each of said wall structures comprises two wall components integrally formed together to form a substantially L-shape half.
 14. The container of claim 10, further comprising one or more Radio Frequency IDentification (RFID) tags affixed on or embedded in any of the base, or wall structures.
 15. The container of claim 14 further comprising a RFID reader able to read one or more RFID tags in the vicinity, wherein the processor can transmit to a base station one or more parameters selected from the group consisting of one or more RFID tag location, one or more RFID tag identification code, cargo information, cargo condition, cargo container condition and time stamp.
 16. A container for loading and transporting a cargo item in a volume comprising: a base structure having a top surface and a bottom surface joined by a thickness, said top surface having a main platform portion, an interface feature surrounding the main platform portion, and an outer edge portion surrounding the interface feature; four identical wall structures, each of said wall structures having an inside surface, an outside surface, a thickness joining the inside and outside surfaces, four inside edges and four outside edges; wherein each wall structure having an interface feature for mating with said interface feature of said base and an interface feature for mating with an interface feature of an adjacent wall to form an enclosure; and a plurality of supports extending from the bottom surface of said base structure; wherein a first of said outside edges of each of said wall structures having an interface feature comprising an extension, said extension having a thickness and a wrapping portion that wraps at a substantially 90° angle about a portion of said corresponding inside edge, forming a channel therebetween the inside and outside surface for receiving a corresponding mating interface feature of one of other said edges of an adjacent wall structure.
 17. The container of claim 16, wherein a plurality of runners are affixed to the plurality of supports.
 18. The container of claim 16, further comprising a pocket on the inside surface of any of the base and wall structures for containing a phase change material.
 19. The container of claim 16, further comprising a bag-like enclosure covering said container for facilitating airport security check.
 20. The container of claim 16, wherein at least one of the surfaces has antimicrobial properties. 